Systems and methods for additive manufacturing of a golf club

ABSTRACT

A golf club head includes a body, a solid portion, and a lattice structure. The body includes a topline, a sole, and an internal cavity arranged between the topline and the sole. The solid portion is arranged within the internal cavity and is fabricated from a solid material. The lattice structure is arranged within the internal cavity and is formed layer by layer via an additive manufacturing process. The lattice structure defines a lattice volume and the solid portion defines a solid volume. An orientation of the lattice structure between the topline and the sole and a volume ratio between the lattice volume and the solid volume define a location of a center of gravity defined by the body.

CROSS REFERENCE TO RELATED APPLICATIONS

Not applicable.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

SEQUENCE LISTING

Not applicable.

BACKGROUND 1. Field of the Disclosure

The present disclosure relates to golf clubs, and more specifically to agolf club head that is manufactured via 3D printing or another type ofadditive manufacturing technique.

2. Description of the Background of the Disclosure

Different types of golf clubs (e.g., irons, drivers, fairway woods,utility irons, hybrid irons/woods, putters, etc.) are used to effectdifferent types of shots, based on a golfer's location and ball lie whenplaying a hole on a golf course. Typically, conventional golf club headsare formed by a forging process, a casting process, a metal injectionmolding process, or a machined process (e.g., milling), and thenmachined, ground, and/or polished to a factory finish standard (e.g.,dimensions, loft, lie, weight, offset, surface finish, aesthetics,etc.).

Forging and casting processes require the use of a mold to provide thegeneral shape or body of a golf club head, which significantly reducesthe ability of a golf club head to be customized or tailored to aspecific set of performance characteristics. For example, the mold usedin a forging or casting process may generally define where a center ofgravity (CG) will be arranged for the golf club head. Post-formingmachining may be implemented to remove material and slightly alter alocation of the CG, but the design of the mold is the limiting factorfor CG location flexibility.

In addition, conventional golf club head manufacturing processes arelimited from a geometric perspective by not being able to readilyproduce club heads with complex geometries. For example, golf club headswith undercut or hollow constructions may be required to be formed via acasting mold, which places volume-based constraints on CG location.Further, the geometric limitations of conventional golf club headmanufacturing processes do not enable club heads to be manufactured withproperties that leverage advantages from various club head types. Forexample, a large-volume, hollow construction club head generallyprovides a higher moment of inertia (MOI) when compared to a low-volume,forged club head (e.g., muscle back), but the low-volume forged clubhead may provide more consistent launch conditions and distancevariability. Conventional club head manufacturing processes are limitedto leveraging one set of advantages based on the type of club head beingmanufactured.

Therefore, a need exits for golf club heads that are modifiable orcustomizable, and that can leverage performance advantages from avariety of club head types in a single club head without therestrictions present in conventional golf club head manufacturingprocesses.

SUMMARY

The present disclosure is directed to golf club heads constructed using3D printing or another type of additive manufacturing technique.

In some embodiments, the present disclosure provides a golf club headthat includes a body, a solid portion, and a lattice structure. The bodyincludes a topline, a sole, and an internal cavity arranged between thetopline and the sole. The solid portion is arranged within the internalcavity and is fabricated from a solid material. The lattice structure isarranged within the internal cavity and is formed layer by layer via anadditive manufacturing process. The lattice structure defines a latticevolume and the solid portion defines a solid volume. An orientation ofthe lattice structure between the topline and the sole and a volumeratio between the lattice volume and the solid volume define a locationof a center of gravity defined by the body

In some embodiments, the present disclosure provides a golf club headincluding a body and a lattice structure. The body includes a topline, asole, and a front face. The lattice structure is formed on a portion ofthe body layer by layer along a build plane via an additivemanufacturing process. When the build plane is oriented parallel to anormal defined by the front face, a lattice build angle defined betweena lattice plane and the build plane is greater than or equal to about 30degrees.

In some embodiments, the present disclosure provides a golf club headincluding a body and a lattice structure. The body includes a topline, asole, and a front face. The front face defines a rear surface thatextends along a plane and the body defines a solid center of gravityplane. The lattice structure is formed on a portion of the body layer bylayer via an additive manufacturing process. The portion of the body isbounded by the plane, the solid center of gravity plane, and anintersection between the plane and the solid center of gravity plane.

In some embodiments, the present disclosure provides a golf club headthat includes a body and a lattice structure. The body includes aninsert wall, a crown, a sole, a heel, and a toe. A head cavity isdefined by the crown, the sole, the heel, and the toe. The latticestructure is disposed within the head cavity and extends from the crownand the sole. The lattice structure is unitary with the body.

In some embodiments, the present disclosure provides a golf club headthat includes a body and a lattice structure. The body includes aninsert wall, a crown, a sole, a heel, and a toe. A head cavity isdisposed within the body. The lattice structure is disposed within thehead cavity and includes segments that extend from the crown and thesole. The lattice structure and the hosel are unitary with the body.

In some embodiments, the present disclosure provides a 3-D printed golfclub head post-printed component that includes a body, one or morematerial deposits, and a lattice structure. The body includes an insertwall, a crown, a sole, a heel, and a toe. A head cavity is disposedwithin the body. The one or more material deposits extend from one ormore of the body and the hosel. The lattice structure is disposed withinthe head cavity and extends from internal surfaces of the body. Thelattice structure and the hosel are unitary with the body.

In some embodiments, the present disclosure provides a process ofmanufacturing a golf club head including the step of generating, via anadditive manufacturing process, a golf club head. Generating the golfclub head includes the steps of printing a first material, layer bylayer, along a first plane, and creating a first blow through aperturethat allows air to pass from a front portion of the golf club head to ahead cavity disposed within a rear portion of the golf club head. Theprocess further includes the steps of blowing excess material out fromwithin the head cavity using the first blow through aperture andremoving excess material formed at one or more material depositsdisposed along the golf club head.

In some embodiments, the present disclosure provides a process ofmanufacturing a golf club head including the step of generating, via anadditive manufacturing process, a golf club head. Generating the golfclub head includes the steps of printing a first material, layer bylayer, to create a body defining a sole, a toe portion, a medialportion, a heel portion, and a head cavity, and creating a first blowthrough aperture that allows air to pass from a front portion of thegolf club head to a rear portion of the club head component. The processfurther includes blowing excess material out from within the head cavityusing the first blow through aperture.

In some embodiments, the present disclosure provides a process ofmanufacturing a golf club head including the step of generating, via anadditive manufacturing process, a golf club head. Generating the golfclub head includes the steps of printing a first material, layer bylayer, along a first plane, and creating a first blow through aperturethat allows air to pass from a front portion of the golf club head to ahead cavity disposed within a rear portion of the golf club head. Theprocess further includes sintering the golf club head by setting thegolf club head into a furnace such that the golf club head is resting ona second plane that defines an angle of between 10 degrees and about 50degrees with respect to the first plane.

In some embodiments, the present disclosure provides a process ofmanufacturing a golf club head that includes the steps of forming, viaan additive manufacturing process, a body of the golf club head byprinting, layer by layer, a boundary that encloses a volume and isformed by at least one layer, and sintering the body to form a solidmaterial within the volume.

In some embodiments, the present disclosure provides a process ofmanufacturing a golf club head that includes the steps of forming, viaan additive manufacturing process, a body of the golf club head. Formingthe body of the golf club head includes the steps of creating a cavityarranged within the body, printing a plug within the cavity that isseparated from internal surfaces defined by the cavity, removing excessmaterial within the cavity, moving the plug to a desired location withinthe cavity, filling the cavity with a filler material.

In some embodiments, the present disclosure provides a process ofmanufacturing a face insert of a golf club head that includes the stepsof forming via an additive manufacturing process, a mold insert,creating a mold from the mold insert formed via the additivemanufacturing process, and molding an insert from the mold insert. Themold insert includes a lattice structure or a ribbed structureprotruding therefrom.

In some embodiments, the present disclosure provides a process ofmanufacturing a golf club head that includes the steps of forming, viaan additive manufacturing process, a body of the golf club head,arranging the body on a sintering support including a face surface and ahosel surface, and sintering the body of the golf club head.

In some embodiments, the present disclosure provides a golf club headthat includes a body formed layer by layer and having a topline, a sole,and an internal cavity arranged between the topline and the sole. Thegolf club head further includes at least one aperture formed through atleast one of a hosel extending from the body, a rear surface of thebody, and a toe portion of the body. The at least one aperture isconfigured to form a flow path that extends along the internal cavityand the at least one aperture.

In some embodiments, the present disclosure provides a sintering supportfor a golf club head. The golf club head includes a front face and ahosel. The sintering support includes a face surface, a hosel surfacethat extends at an angle from one side of the face surface, and asupport wall that extends from a side of the face surface opposite tothe hosel surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top, front, and left side isometric view of a putter-typeclub head in accordance with the present disclosure;

FIG. 2 is a top, rear, and right side of the putter-type club head ofFIG. 1 ;

FIG. 3 is a front elevational view of the putter-type club head of FIG.1 ;

FIG. 4 is a rear elevational view of the putter-type club head of FIG. 1;

FIG. 5 is left or toe side elevational view of the putter-type club headof FIG. 1 ;

FIG. 6 is a right or heel side elevational view of the putter-type clubhead of FIG. 1 ;

FIG. 7 is a top plan view of the putter-type club head of FIG. 1 ;

FIG. 8 is a bottom plan view of the putter-type club head of FIG. 1 ;

FIG. 9 is a top, front, and left side isometric view of the putter-typeclub head of FIG. 1 in a post 3D-printed state and a post-printed state;

FIG. 10 is a bottom, rear, and right side isometric view of thepost-printed putter-type club head of FIG. 9 ;

FIG. 11 is a front elevational view of the post-printed putter-type clubhead of FIG. 9 ;

FIG. 12 is a left side elevational view of the post-printed putter-typeclub head of FIG. 9 ;

FIG. 13 is a rear elevational view of the post-printed putter-type clubhead of FIG. 9 ;

FIG. 14 is a top, rear, and right side cross-sectional view takenthrough line 14-14 of FIG. 5 ;

FIG. 15 is another top, rear, and right side cross-sectional view takenthrough line 15-15 of FIG. 5 ;

FIG. 16 is still another top, rear, and right side cross-sectional viewtaken through line 16-16 of FIG. 5 ;

FIG. 17 is a side cross sectional view taken through line 17-17 of FIG.3 ;

FIG. 18 is a side cross sectional view taken through line 18-18 of FIG.3 ;

FIG. 19 is a side cross-sectional view taken through line 19-19 of FIG.11 ;

FIG. 20 is a side cross-sectional view taken through line 20-20 of FIG.3 ;

FIG. 21 is a top, front, and left side view of a face insert that isinsertable into the face cavity shown in the post-printed putter-typeclub of FIGS. 9-13 ;

FIG. 22 is a side elevational view of the face insert of FIG. 21 ;

FIG. 23 is a top, rear, and left side isometric view taken through line23-23 of FIG. 4 ;

FIG. 24 is a rear view of an iron-type golf club head according to oneaspect of the present disclosure;

FIG. 25 is a front view of the iron-type golf club head of FIG. 24 ;

FIG. 26 is a rear view of the iron-type golf club head of FIG. 24 withan external shell transparent and a lattice structure extending over aninternal cavity;

FIG. 27 is a cross-sectional view of the iron-type golf club head ofFIG. 26 taken along line 27-27;

FIG. 28 is a rear view of the iron-type golf club head of FIG. 24 withan external shell transparent and a lattice structure extending over aportion of an internal cavity adjacent to a sole;

FIG. 29 is a cross-sectional view of the iron-type golf club head ofFIG. 28 taken along line 29-29;

FIG. 30 is a rear view of the iron-type golf club head of FIG. 24 withan external shell transparent and a lattice structure extending over aportion of an internal cavity adjacent to a topline;

FIG. 31 is a cross-sectional view of the iron-type golf club head ofFIG. 30 taken along line 31-31;

FIG. 32 is a top, front, right isometric view of an iron-type golf clubhead including a lattice structure with a gap formed between the latticestructure and a face insert with the face insert hidden;

FIG. 33 is a cross-sectional view of the iron-type golf club head ofFIG. 32 taken along line 33-33;

FIG. 34 is a cross-sectional view of the iron-type golf club head ofFIG. 32 taken along line 34-34 illustrating with a weight bar;

FIG. 35 is a cross-sectional view of the iron-type golf club head ofFIG. 34 taken along line 35-35;

FIG. 36 is cross-sectional view of an iron-type golf club head includinga lattice structure supporting a front face;

FIG. 37 is a cross-sectional view of the iron-type golf club head ofFIG. 31 taken along line 37-37;

FIG. 38 is a cross-sectional view of the iron-type golf club head ofFIG. 31 illustrating a slot formed in a rear side;

FIG. 39 is an enlarged view of a portion of the cross-sectional view ofthe iron-type golf club head of FIG. 29 ;

FIG. 40 is a cross-sectional view of the iron-type golf club head ofFIG. 29 taken along line 40-40;

FIG. 41 is a schematic illustration of a portion of a lattice structureaccording to the present disclosure;

FIG. 42 is a schematic illustration of an intersection point of alattice structure according to the present disclosure;

FIG. 43 is a rear view of an iron-type golf club head having an externallattice structure according to the present disclosure;

FIG. 44 is a cross-sectional view of the iron-type golf club head ofFIG. 43 taken along ling 44-44;

FIG. 45 is a rear view of the iron-type golf club head of FIG. 43 with afiller material in the external lattice structure;

FIG. 46 is a rear view of an iron-type golf club head illustrating asolid center of gravity plane according to the present disclosure;

FIG. 47 is a rear view of the iron-type golf club head of FIG. 46including a lattice structure;

FIG. 48 is a top, back, right isometric view of the iron-type golf clubhead of FIG. 47 ;

FIG. 49 is a right side view of the iron-type golf club head of FIG. 47;

FIG. 50 is a cross-sectional view of the iron-type golf club head ofFIG. 47 taken along line 50-50;

FIG. 51 is a top view of the iron-type golf club head of FIG. 47 ;

FIG. 52 is a partial cross-sectional view of the iron-type golf clubhead of FIG. 51 taken along line 52-52;

FIG. 53 is a top view of the iron-type golf club head of FIG. 47 havinga topline protrusion that covers the lattice structure along thetopline;

FIG. 54 is a partial cross-sectional view of the iron-type golf clubhead of FIG. 53 taken along line 54-54;

FIG. 55 is a schematic illustration of a portion of a golf club headincluding a plug manufactured within a cavity;

FIG. 56 is a schematic illustration of the portion of the golf club headof FIG. 55 showing the movability of the plug;

FIG. 57 is a schematic illustration of a generally rectangular boundarymanufactured around a powdered metal filler;

FIG. 58 is a schematic illustration of a generally round boundarymanufactured around a powdered metal filler;

FIG. 59 is a schematic illustration of a generally oval or ellipticalboundary manufactured around a powdered metal filler;

FIG. 60 is a rear view of a front face or striking face of a wood-typegolf club head including a lattice structure;

FIG. 61 is a rear view of a front face or striking face of a wood-typegolf club head including a ribbed structure;

FIG. 62 is a rear view of a front face or striking face wax mold for awood-type golf club head including a ribbed structure;

FIG. 63 is a rear view of a front face or striking face for a wood-typegolf club head formed from a casting made from the wax mold of FIG. 62 ;

FIG. 64 is a top, back, right isometric view of a iron-type golf clubhead wax mold according to the present disclosure;

FIG. 65 is a front view of a 3-D structure of the iron-type golf clubhead wax mold of FIG. 64 ;

FIG. 66 is a back view of a 3-D structure of the iron-type golf clubhead wax mold of FIG. 65

FIG. 67 is a top, front, left isometric view of a sintering supportaccording to one aspect of the present disclosure;

FIG. 68 is a front view of the sintering support of FIG. 67 ;

FIG. 69 is a right side view of a sintering support according to anotheraspect of the present disclosure; and

FIG. 70 is a left side view of a sintering support according to thepresent disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

The present disclosure is directed to golf club heads that are producedusing an additive manufacturing process (i.e., printed layer by layer).In particular, a golf club head of the present disclosure includes aclub head body that is manufactured using an additive manufacturingprocess and may be fabricated from a metal material or a metal alloy. Insome embodiments, the club head body may include a segmented or latticeportion that is created during the additive manufacturing process and,therefore, is formed integrally with the club head body (i.e., thelattice portion and the club head body are a unitary component). Ingeneral, the incorporation of a segmented or lattice portion enablesvarious material and/or performance characteristics of a golf club headto be selectively manipulated to achieve, for example a desired CGlocations, MOI's, mass properties, face flex, distance variability,launch conditions, aesthetics, among other things.

The use of the terms “segmented portion,” “lattice portion,” or “latticestructure,” herein refer to portions of a golf club head that are formedby one of a plurality of interconnected segments, interconnected shapes,or connected surfaces. In some embodiments, the plurality ofinterconnected segments, interconnected shapes, or connected surfacesmay be formed integrally with a club head body by an additivemanufacturing process. In some embodiments, the lattice portion maydefine at least one cutout, or absence of material, that is formedwithin a unit cell (e.g., a repeated pattern defined by the latticestructure). The use of a lattice portion within a golf club head mayallow various manufacturing and performance characteristics to bemodified or customized. For example, a lattice portion may define asubstantially reduced weight or density when compared to a solidmaterial. As such, the placement of a lattice portion within a golf clubhead may be varied using an additive manufacturing process toselectively locate the CG of a golf club head in a desired location. Inaddition, the incorporation of a lattice portion into a golf club headmay reduce the overall volume of material needed to manufacture the golfclub head.

The golf club heads disclosed herein may be manufactured using one ormore of a variety of additive manufacturing processes. For example, agolf club head according to the present disclosure may be at leastpartially fabricated using a metal powder bed fusion additivemanufacturing processes that fuses, melts, or bonds metal powderparticles layer by layer along a build plane. In some embodiments, themetal powder particles may be melted or fused by a laser that formscross-sections of a golf club head layer by layer along a build plane.In some embodiments, the metal powder particles may be melted or fusedby an electron beam or ultrasonic energy to form cross-sections of agolf club head layer by layer along a build plane. In some embodiments,the metal powder particles may be bonded to form cross-sections of agolf club head layer by layer along a build plane via the deposit (e.g.,printing) of a binder.

The various methods of additive manufacturing used to manufacture a golfclub heads according to the present disclosure may include binderjetting, direct energy deposition, selective laser melting (SLM), directmetal laser sintering (DMLS), fused deposition modeling (FDM), electronbeam melting, laser powered bed fusion (LPBF), ultrasonic additivemanufacturing, material extrusion, material jetting, Joule printing,electrochemical deposition, cold spray metal printing, DLP metalprinting, Ultrasonic Consolidation or Ultrasonic Additive Manufacturing(UAM), LENS laser-based printing, electron beam freeform fabrication(EBF3), laser metal deposition, or carbon fiber additive manufacturing.

Referring now to FIGS. 1-8 , a putter-type club head 40 is shown inaccordance with the present disclosure that may be formed through anadditive manufacturing process. The club head 40 defines a body 42 and aface insert 44, which may be coupled to one another after machining ofthe body 42, as will be discussed in greater detail below. The body 42defines a toe side 46, a heel side 48, a front side 50, a top side orcrown 52, a bottom side or sole 54, and a rear side 56. Referring toFIG. 1 , the body 42 of the club head 40 is formed from metallic and/ornon-metallic materials. For example, the body 42 may be formed from anyone of or a combination of aluminum, bronze, brass, copper, stainlesssteel, carbon steel, titanium, zinc, polymeric materials, and/or anyother suitable material.

The body 42 includes a front portion 60 and a rear portion 62, the frontportion 60 defining a face insert cavity 64 (see FIGS. 9 and 11 ), thatis configured to receive the face insert 44. The face insert 44 definesa striking surface 68. The striking surface 68 comprises an entirety ofthe front surface of the face insert 44, and is configured forcontacting a golf ball. A peripheral edge 70 of the face insert 44aligns with an inset edge 72 of the face cavity 64 (see FIG. 9 ) of thebody 42. The striking surface 68 further defines a first surface 74, asecond surface 76, a third surface 78, and a fourth surface 80 thatdefine various angles with respect to a plane normal to the ground whenthe club head 40 is at address. The first surface 74 of the strikingsurface 68 may define an angle of about 1 degree, the second surface 76may define an angle of about 2 degrees, the third surface 78 may definean angle of about 3 degrees, and the fourth surface 80 may define anangle of about 4 degrees. However, in come embodiments the surfaces 74,76, 78, 80 may define different angles, or may define the same angle. Tothat end, the striking surface 68 may comprise only a single, planarsurface that defines a constant angle.

Referring to FIG. 3 , the body 42 defines a toe portion or region 84, amedial portion or region 86, and a heel portion or region 88. The heelregion 88 of the body 42 includes a hosel 90 that extends upwardtherefrom. In some embodiments, the heel region 88 defines an aperture(not shown) that is disposed within the heel region 88, which isconfigured to receive and secure a shaft (not shown) of the golf club(not shown).

Referring specifically to FIGS. 3 and 4 , the heel side 48 of the body42 is rounded and extends from a lower heel-side inflection point 96 toan upper heel-side inflection point 98. The sole 54 of the body 42intersects with the heel side 48 at the lower heel-side inflection point96, while the crown 52 of the body 42 intersects with the heel side 48at the upper heel-side inflection point 98. The sole 54 defines a heelsegment 100, a medial segment 102, and a toe segment 104. The heelsegment 100 and the toe segment 104 are generally angled and planar whenviewed in elevation, while the medial segment 102 connects the toesegment 104 with the heel segment 100 and is generally planar. Further,portions of the medial segment 102 are parallel with respect to theground (not shown) when the head 40 is at address.

A portion of the toe segment 104 curves upward to a lower toe-sideinflection point 108 where the toe segment 104 of the sole 54 intersectswith the toe side 46. A portion of the toe side 46 curves upward andinward, in a direction of the hosel 90, and defines a generally straightportion of the toe side 46 that extends to an upper toe-side inflectionpoint 110. The top side 52 intersects with the toe side 46 at the uppertoe-side inflection point 110. When viewed from the front, the top side52 extends laterally from the upper toe-side inflection point 110 to theupper heel-side inflection point 98, and is interrupted by the hosel 90.

Referring to FIG. 3 , the toe region 84, the medial region 86, and theheel region 88 are defined by vertical lines or planes P1 and P2 thatextend through intersections of the heel segment 100 and the medialsegment 102, and the toe segment 104 and the medial segment 102,respectively. The hosel 90 is located within the heel region 88, andextends vertically from the top side 52. In some embodiments, the hosel90 may be at least partially disposed within the medial region 86. Thehosel 90 includes a plurality of cutouts 112 defined within a hosel arm114, which are generally in the shape of alternating triangles. Thecutouts 112 may extend entirely through a width of the hosel 90, or thecutouts 112 may not extend entirely through the hosel 90, i.e., in thepresent embodiment, the hosel 90 does not include apertures that extendcompletely through the hosel arm 114. In some embodiments, the cutouts112 may align on a front and rear of the hosel (see FIGS. 3 and 4 ). Inalternative embodiments, only the front side of the hosel 90 may includethe cutouts 112 or only the rear side of the hosel 90 may include thecutouts 112. A shaft bore 116 extends from the hosel 90, the shaft bore116 being sized and shaped to receive a shaft (not shown), or an elementthat may be coupled with the shaft.

Referring again to FIG. 1 , a surface defining the front region 60 ofthe top side 52 is generally planar, while surfaces defining the rearregion 62 of the top side 52 comprise a plurality of depressions,recesses, and other features. The front region 60 and the rear region 62of the top side 52 are separated by a seam or groove 120 that extendsfrom the heel side 48 to the toe side 46. However, in embodiments thatdo not include the seam or groove 120, the front region 60 and the rearregion 62 are defined by a plane that extends vertically through theseam 120. A shaft cavity 122 is further shown in FIG. 1 , the shaftcavity 122 defining a cylindrical cavity within the shaft bore 116 intowhich the shaft (not shown) may be inserted. The shaft cavity 116 may bemodified or formed to achieve any number of putter shaft positions,including heel, centered, and hosel offset.

Still referring to FIG. 1 , the face insert 44 is attached to or pressfit within the insert cavity 64 of the body 42. In some embodiments, theface insert 44 is secured and anchored via an interlocking structure(not shown). As provided in the cross-sectional views below, a bondingagent or adhesive 126 (see FIGS. 17 and 23 ) may be used to help securethe face insert 44 into the face cavity 64. Regardless of the type ofretention mechanism used, the face insert 44 is fixed securely withinthe face cavity 64 of the body 42.

Referring now to FIG. 2 , a rear view of the club head 40 is shown. Ahead cavity 130 is visible from the rear view, which houses a firstweight 132, a second weight 134, and an internal lattice structure 136.In some embodiments, the club head 40 may not include the first weight132 and the second weight 134. For example, the club head 40 may includesolid material, the internal lattice structure 136, or a cavity (i.e.,no material) in place of the first weight 132 and the second weight 134.In the illustrated embodiment, the lattice structure 136 is unitary withthe body 42, i.e., the lattice structure 136 comprises the same materialand is manufactured at the same time as they body 42. The first weight132 and the second weight 134 are separate components, which maycomprise tungsten or another type of metal. The lattice structure 136 ispreferably 3D printed with the rest of the body 42. However, in certainembodiments, the lattice structure 136 may comprise a separate cartridgethat is insertable into the cavity 130. The first weight 132 is locatedwithin the heel region 88, the second weight 134 is located within thetoe region 84, and the lattice structure 136 extends across the heelregion 88, the toe region 84, and the medial region 86.

Still referring to FIG. 2 , the front portion 60 and the rear portion 62of the club head 40 are shown separated by the groove 120. As notedabove, outer sides defining the front portion 60 are generally planar,while the rear portion 62 defines a rear upper side 140 and an insetregion 142. The inset region 142 defines a first or upper inset region144 and a second or lower inset region 146. The upper inset region 144is defined by a first inset side 148, which is a beveled edge thatextends downward from the rear upper side 140 toward the sole 54. Afirst inset platform 150 extends from portions of the first inset side148, the first inset platform 150 being generally parallel with respectto the rear upper side 140. The first inset side 148 is generallyU-shaped, and defines a periphery of the first inset region 144.

The second inset region 146 is also shown in FIG. 2 , the second insetregion 146 being defined by second inset sides 152 that are disposed onopposing sides of an alignment platform 154. The alignment platform 154includes a plurality of alignment notches or features 156. The pluralityof alignment features 156 may comprise any number and any type ofdesigns that are sufficient to aid a golfer to align the putter-typegolf club head 40 with a cup. In the present embodiment, the alignmentfeatures 156 are notches that are three dimensional features; however,in alternative embodiments, the alignment features 156 may be planarfeatures, and may be painted along the alignment platform.

A central alignment feature 158 is disposed centrally along thealignment platform 154, and is configured to allow a golfer to align theputter head 40 with the cup before striking a golf ball (not shown). Awindow 160 is disposed within the second inset region 146, between thesecond inset sides 152, the window 160 being an opening that allows forair to enter the cavity 130 above the alignment platform 154. As will bediscussed in greater detail below, it is preferable to include blowthrough apertures along varying portions of a 3D printed putter head toallow excess material to be removed from the putter head 40 during themanufacture thereof, i.e., de-caking. It is for at least this reasonthat various apertures may be included along portions of the club 40during at least some stages of the manufacturing process. Any commercialblower or air moving device may be used to blow excess material fromwithin the putter head 40.

In some embodiments, a vacuum may be used to suck excess material fromwithin the putter head 40. In other embodiments, one or more toolsincluding brushes, chisels, picks, or other implements are used tomanually remove powder from within the putter head 40. Duringpost-printing processing, excess powder may be vacuumed or blown off ofa build box that may include one or more of the putter heads 40. Afterinitially vacuuming or blowing, manual material removal is done toremove excess material from the putter head 40. At this stage, remainingexcess powder may be removed with one or more of the above-noted tools.

Still referring to FIG. 2 , the profiles of the alignment features 156may define a variety of shapes or cross sections that are sufficient todelineate the size and shape of the alignment features 156. Thealignment features 156 may define shallow grooves in the alignmentplatform 154, the depths of which may be selected to sufficiently enableapplication and retention of a paint fill. In some embodiments, thealignment features 156 are filled with a paint or other organic coatingthat may be distinguished in appearance from its surroundingenvironment. In some embodiments, the grooves are partially or entirelyfilled with a material distinguished in appearance from its surroundingenvironment, e.g., a colored opaque or translucent polymer.

Referring now to FIG. 4 , the first and second weights 132, 134, thewindow 160, the alignment platform 154, the first inset side 148, andthe lattice structure 136 are shown in greater detail. The cutouts 112along the hosel 90 are also visible in the rear view of FIG. 4 . Thefirst weight 132 and the second weight 134 are shown snugly disposedbetween an upper retention feature 166 and a lower retention feature168. The upper and lower retention features 166, 168 generally definecylindrical portions having voids therebetween that allow the first andsecond weights 132, 134 to be inserted therein, such that the first andsecond weights 132, 134 fit snugly between the upper and lower retentionfeatures 166, 168. In some embodiments, a lock and key feature (notshown) within the cavity 130 retains the first and second weights 132,134 in place, so as to prevent undesired rotation of the first andsecond weights 132, 134.

While the first and second weights 132, 134 are shown having aparticular diameter, varying types and sizes of weights arecontemplated. In some embodiments, the weights 132, 134 are removable,and may be removed and replaced by a user or a technician. As shown inthe figures, the first and second weights 132, 134 define an outerdiameter D1 that is identical, and that is larger than an outer diameterD2 of the upper and lower retention features 166, 168. Further, whilethe first and second weights 132, 134 are shown being disposed entirelywithin the heel region 88 and the toe region, respectively, it iscontemplated that the first and second weights 132, 134 may extendacross one or more of the regions 100, 102, 104.

Still referring to FIG. 4 , the lattice structure 136 is shown ingreater detail. The lattice structure 136 is defined by a plurality ofangled segments 172, a plurality of horizontal segments 174, and aplurality of vertical segments 176, which combine to form a plurality oftriangles or triangular portions. Air spaces are formed between theplurality of segments 172, 174, 176, which may be filled with a fillermaterial in some embodiments, as discussed in greater detail below. Anoutermost or rearmost row 178 (see FIG. 23 ) of the lattice structure136 defines four separate right triangles, each of the right trianglesbeing partially defined by one of the angled segments 172 and one of thevertical segments 176. An innermost row 180 is also shown in FIG. 23 .Curved rounds are defined at intersection points 182 of the segments172, 174, 176. The intersection points 182 are rounded (e.g., define acurvature, or a radius of curvature, and are not formed by theintersection of one or more straight lines) rather than cornered formanufacturing purposes. For example, it has been found that the overallstrength of the lattice structure 136 is increased with the inclusion ofcurved rounds at the intersection points 182. Through testing, it hasbeen determined that when the intersection points 182 define sharpcorners, the lattice structure is more likely to crack or break. Addingradii to sharp edges within geometry that is formed through 3D printingsolves several issues, including: helping with de-caking (helps againstgreen part destruction when blowing air against the lattice structure136), reducing sintering drag, and avoiding stress concentrations byadding radii on the edges of the lattice structure 136.

In some embodiments, the club head 40 may be 3D printed using binderjetting, which is a cost-effective way to produce low batch productionwith geometries that cannot be efficiently manufactured usingconventional manufacturing methods. Metal binder jetting buildscomponents by depositing (e.g., printing) a binding agent onto a layerof powder through one or more nozzles. The club head 40 is 3D printed,layer by layer, along of a first or build plane, as discussed in greaterdetail herein. The printing occurs at room temperature, or slightlyabove room temperature, which means that thermal effects are typicallynot present in the final printed components. However, printing may occurat higher or lower temperatures. Metal binder jetting is a two-stageprocess, and involves a printing step and an essential post-processingstep (sintering). Binder jetting involves spreading a thin layer ofmetal powder over a build platform, selectively depositing droplets of abinding agent that bonds the metal powder particles, and repeating theprocess until the build is complete. Once the build process is complete,the printed part may be excavated from the powder in the build platformand subsequently removed from the build platform. The result of theprinting process is a part that is in the so-called “green” state, whichis moved to a post-processing step to remove the binding agent andcreate the metal part.

After the club head 40 has been printed, additional intermediate stepsmay be required before the club head 40 enters into a sintering step. Insome embodiments, the part may need to go through a curing stage toallow the binder to set properly. Still further, in some embodimentsbefore sintering, a de-binding step may be required to drive out anyremaining binder. However, in some embodiments the curing step and thede-binding step may not be needed.

There are two variations for the post-processing step. When usinginfiltration, the green part is first washed off from the binding agentto create a “brown” part with significant internal porosity, e.g., 70%.The brown part is then heated in an oven in the presence of alow-melting-point metal, such as bronze. The internal voids are filled,resulting in a bi-metallic part. When using sintering, the green part isplaced in an industrial furnace. There, the binder is first burned offand the remaining metal particles are sintered together. The result is afully metal component having dimensions that are approximately 20%smaller than the original green part. To compensate for shrinkage, theparts are printed larger, i.e., about 10%, or about 15%, or about 20%,or about 25%, or about 30% larger than final club head 40. In someembodiments, the parts are printed between about 10% and about 30%larger, or between about 15% to about 25% larger, or between about 16%and about 20% larger. In some embodiments, the larger dimensions definedby the printed part (pre-sintering) may leave enough material to enablea printed club head to meet factory finish standards. In someembodiments, the golf club head may be machined (e.g., via milling orturning) post-sintering to obtain, for example, the loft, lie, weight,dimensions, volume, shape, etc., defined by the factory finish.

In some embodiments, the club head 40 may be 3D printed using DMLS, oranother one of the above-listed additive manufacturing techniques. Inembodiments where the club head 40 is created using DMLS, a high poweredlaser is used to bond metal particles together, layer by layer, tocreate the club head 40. While the process of DMLS involves fusingmaterial particles to one another on a molecular level, many differentmetal alloys are compatible with this type of additive manufacturingtechnique. After printing, i.e., after a laser has selectively bondedthe metal particles to one another, the club head 40 is cooled and loosepowder is extracted. Post-processing steps may involve stress relief viathermal cycling, machining, heat treatment, or polishing. Various otherpost-processing steps may also be involved through printing of the clubhead 40 using DMLS or any of the above techniques.

For example, in some additive manufacturing processes (e.g., DMLS) oneor more supports (not shown) may be included on the club head 40 duringprinting to prevent the part from warping. Further, in DMLS, because theprinted club head 40 is bonded to a build plate, a method of cutting maybe required to cut the printed parts from the build plate. Electricaldischarge machining (EDM) may be used to cut the printed parts from thebuild plate. Cutting or removing the parts may be required when usingDMLS to build the parts, but may also be required when using other formsof additive manufacturing such as directed energy deposition DED ormaterial extrusion.

Referring now to FIGS. 5 and 6 , side profiles of the club head 40 areshown in detail. More specifically, the toe side 46 is shown in FIG. 5 ,while the heel side 48 is shown in FIG. 6 . The sole 54 or underside ofthe club head 40 is visible in the figures, and a plurality of designelements are visible spanning the front portion 60 and the rear portion62 of the sole 54. Fastener apertures 190 are also visible, the fastenerapertures 190 being sized and shaped to allow fasteners 192 (see FIG. 8) to be inserted into the fastener apertures 190, to thereafter retainthe first and second weights 132, 134 in position. The fastenerapertures 190 are formed after the 3D printing process has occurred,i.e., in a post-printing state, as will be discussed in greater detailhereinafter below. Still referring to FIGS. 5 and 6 , the hosel 90 isshown in greater detail, the hosel 90 being disposed at an angle offsetfrom a plane that is normal with respect to the ground. The front faceof the body 42 is also shown disposed at an offset angle with respect toa plane that is normal with respect to the ground when the club head 40is at address. The front face 50 and the hosel 90 are angled in opposingdirections with respect to the plane that is normal with respect to theground when the club head 40 is at address.

Referring now to FIGS. 7 and 8 , top and bottom views of the club head40 are shown in detail. Referring specifically to FIG. 7 , the frontportion 60 and the rear portion 62 are clearly shown being separated bythe groove 120. However, as noted above, in embodiments that do notinclude the groove 120, the front portion 60 and the rear portion 62 areseparated by a plane that extends through the groove 120. The shaft bore116 and shaft cavity 122 are also shown in greater detail. The shaftcavity 122 is disposed at an offset angle with respect to an axis normalto the ground when the club head 40 is at address. The planar portionsalong the front region 60 of the body 42 are also shown clearly in FIG.7 . Further, the first and second inset regions 144, 146 are depicted,and the plurality of alignment features 156 are shown surrounding thecentral alignment feature 158. As illustrated in FIGS. 7 and 8 , acutout region 196 is visible, the cutout region 196 following a profileof the second inset sides 152 and an outer edge 198 of the alignmentplatform 154 when viewed in the plan views of FIGS. 7 and 8 . While theterm “cutout” is used herein, it should be appreciated that themanufacturing techniques utilized to create the club head 40 may or maynot require the physical removal or grinding down of some portions,while certain portions do have to be removed or otherwise grinded down,as discussed with respect to FIGS. 9-13 below. As such, a “cutout” mayrefer to a portion that is devoid of material, not necessarily a portionthat has had material that has been physically removed therefrom.

Referring to FIG. 8 , a bottom view of the club head 40 is shown.Various design features 200 are shown spanning the front portion 60 andthe rear portion 62 of the sole 54, and two fasteners 192 are shownalong the rear portion 62 of the sole 54, the fasteners 192 beingaligned with the weights 132, 134. The cutout region 196 is visible inFIG. 8 , which is shown defining various curved and straight surfaces.The fasteners 192 are shown disposed on opposing sides of the cutoutregion 196. In some embodiments, the fasteners 192 are configured to beremoved. However, in some embodiments, the fasteners 192 are permanentlyaffixed to the club head 40 via an adhesive or another type of retentionmechanism. The particular location of the fastener apertures 190 may beadjusted depending on a desired weight or center of gravity (CG) of theclub head 40. Still further, additional weights (not shown) may be addedalong the club head During manufacturing of the club head 40, theweights 132, 134 are inserted into the head cavity 130 and secured tothe club head 40 via one or more fasteners, an adhesive, or another typeof securement mechanism.

Referring now to FIGS. 9-13 , a golf club head post-printed component204 is shown. The post-printed component 204 depicts the club head 40 ina post-printed, pre grinded state. Further, the post-printed component204 is shown without the face insert 44 applied to the body 42, thus,the face insert cavity 64 is visible, the face insert cavity 64 being atleast partially defined by an insert wall 206. The post-printedcomponent 204 is preferably formed using binder jetting, as describedabove. The post-printed component 204 may be printed at an angle that isoffset by about 30 degrees with respect to the orientation shown in FIG.12 , i.e., 30 degrees counterclockwise. In some embodiments, thepost-printed component may be printed at an angle of between about 5degrees and about 60 degrees offset, or between about 10 degrees andabout degrees offset, or between about 20 degrees and about 40 degreesoffset from the orientation shown in FIG. 12 , i.e., from when thecomponent 204 is at address.

When manufacturing a golf club head via an additive manufacturingprocess, it is beneficial to ensure that the layer lines created duringthe additive manufacturing process avoid sharp surface interfaces (e.g.,corners, edges, etc.) that fall along layer line edges. For example, ina binder jetting process, if a golf club head is printed such that thefront face or striking surface is arranged parallel to the build plane(e.g., the front face is printed flat), the printed club head may showvisible layer lines at shallow elevation changes, which may producesharp corners that fall directly on a layer line edge and create cracks.The rotational offset that the post-printed component 204 is printed at,described above, may aid in preventing the printing of visible layerlines with sharp corners that fall on the layer line edge. In addition,printing at the rotation offset may prevent cracking of the green partduring the print or sintering stages.

Further, the rotational offset that the post-printed component 204 isprinted at may also aid in Z-height limitations in, for example, abinder jetting process. For example, a thickness in the Z-direction(i.e., a height defined by a layer perpendicular to the build plane) maybe reduced as the layers increase in Z-height during a binder jettingprocess. That is, the lower layers lay define an increased thicknessrelative to the upper layers due to weight of the overall structureweighing down on the lower layers. By printing the post-printedcomponent at a rotational offset, the total Z-height defined by thecomponent during the build is reduced, when compared to printing thecomponent in the orientation of FIG. 12 .

In some embodiments, the club head 40 may be printed in multiplecomponents. For example, the hosel 90 and the body 42 may be printed,via binder jetting, as separate components. In this way, for example,the Z-height defined by the components being printed may be furtherreduced and the build efficiency (i.e., the amount of components printedduring a build job) may be increased.

Referring specifically to FIG. 9 , the face insert cavity 64 is shown ingreater detail. The face insert cavity 64 is defined by the peripheraledge 70 that generally corresponds with an outer profile of the faceinsert 44 (see FIG. 1 ) and the insert wall 206. A material deposit 208is centrally disposed within the face insert cavity 64 and extendsoutward from the insert wall 206, the material deposit 208 defining aplanar surface 210 and an outwardly extending platform. The materialdeposit 208 is intended to be machined off of the club head 40. However,in some embodiments, only a portion of the material deposit 208 may beremoved from the post-printed component 204. The centrally disposedmaterial deposit 208 may be provided or printed along what may beconsidered the “sweet spot” of the club head 40. As a result, themachining of the centrally disposed material deposit 208 may allow forremoval to enhance or otherwise modify the sweet spot. The location andsize of any remaining portion of the material deposit 208 within theinset cavity may affect the characteristic time (“CT”) of the club head40.

Still referring to FIG. 9 , a first or toe-side aperture 214 and asecond or heel-side notch 216 are shown within the insert cavity 64. Asnoted below, the heel-side notch 216 becomes the heel-side aperture 216after processing of the post-printed component 204. The toe-sideaperture 214 is sized and shaped to allow air to flow through thepost-printed component 204 during the manufacturing process to allowcertain post-production material to be removed from the post-printedcomponent 204. The toe-side aperture 214 may also be sized and shaped toreceive one or more portions of the face insert 44, for example, in alock-and-key fashion, so as to retain the face insert in place withinthe insert cavity 64. During the post-processing step of manufacturing,the heel-side notch 216 is machined to become a heel-side aperture 216,similar to the toe-side aperture. In some embodiments, there may be oneor more additional apertures that are provided along the insert wall206. Since the particular face insert 44 described herein has regionsdefining different degrees, the face insert cavity 64 may be sized andshaped differently to receive alternatively shaped inserts.

Referring now to FIG. 10 , the sole 54 of the post-printed component 204is shown in greater detail. A rear side of the hosel 90 is also shown ingreater detail. As shown in this particular view, the post-printedcomponent 204 includes several locations with additional materialdeposits 208 that are ultimately removed during a post-processing step.However, since the post-printed component 204 is depicted in a formafter having been 3D printed, various portions of the post-printedcomponent 204 include the material deposits 208, which are machined offor are otherwise removed during a post-printing process. For example,and still referring to FIG. 10 , the material deposits 208 along thesole 54 that are cylindrical in nature are formed where the fastenerapertures 190 are disposed in the final form of the club head 40. Stillfurther, one of the material deposits 208 is shown extending outwardlyfrom the hosel 90. The material deposits 208 may be formed in varyinglocations along the post-printed component 204, which may be exist after3D printing because of one or more factors associated with 3D printing.For example, certain material deposits may be formed to enhance certainstructural features of the post-printed component 204 duringpost-processing steps. Still further, material deposits may be formed orprinted because of the technique that is utilized for manufacturing thepost-printed component 204, or to aid in verifying specifications,machining, polishing (as guides), or fixturing the post-printedcomponent.

In some embodiments, the one or more material deposits 208 may beprovided so as to act as a reference circle to indicate a center of adesired bored or tapped hole. For example, the material deposits 208located along the sole 54 are concentric circles that indicate where thehole should be drilled through in which the weights are located. Thematerial deposits 208 may be a specified height so as to more easilymachine portions of the post-printed component 204.

Referring to FIG. 11 , the material deposits 208 along the sole of thepost-printed component 204 are shown more clearly. The toe-side aperture214 is also shown in greater detail, and the upper and lower retentionfeatures 166, 168 for the first weight 132 are visible through thetoe-side aperture 214. Guide holes 218 are shown disposed along thecentrally raised planar surface 210. A centered hole 219 is also shownin FIG. 11 , which, in combination with the guide holes 218, are used tocenter the post-printed component 204 for various post-printingprocesses. For example, the centered hole 218 is located in thegeometric center of the post-printed component 204, and may be used as amachining “chuck” to elevate the post-printed component 204 and allowfor machining of the various surfaces of the post-printed component. Byplacing the hole 219 centrally along the surface 210, variousefficiencies are achieved since it is preferable to elevate thepost-printed component 204 by machining surfaces to tighter tolerances.

Referring to FIG. 12 , the material deposit 208 that extends from theshaft bore 116 is shown in greater detail. Further, the shaft cavity 116is entirely filled in, i.e., there is no shaft cavity 122 until thematerial disposed within the shaft bore 116 has been machined out tocreate the shaft cavity 122. A rear view of the post-printed component204 is shown in FIG. 13 , where the material deposits 208 are shown ingreater detail. The heel-side aperture 216 is also visible through FIG.13 , the heel-side aperture 216 being aligned with the upper and lowerretention features 166, 168 within the heel region 88. The latticestructure 136 is visible in FIG. 13 , which is generally in the sameconfiguration as it is within the club head 40. While the foregoingdescription relating to the post-printed component 204 includes variousaspects that are not shown or included within the club head 40,alternative variations of the post-printed component 204 arecontemplated that can achieve various aspects of the club head 40. Oncethe post-printed component 204 is ready for sintering, the post-printedcomponent is placed into a sintering furnace face down, i.e., with theface cavity 64 facing downward. In some embodiments, the post-printedcomponent 204 may be sintered in an orientation other than face down.For example, the post-printed component 204 may be sintered sole down(i.e., with the sole 54 facing downward). Alternatively a sinteringsupport (see FIGS. 67-70 ) may be used to support the post-printedcomponent 204 in a desired rotation orientation relative to gravity.

Now turning to the views of FIGS. 14-17 , cross sectional views of theclub head 40 are shown to illustrate the internal structure within theclub head 40. Referring specifically to FIG. 14 , some of the angledsegments 172 of the lattice structure 136 are shown extending from aninner surface 220 of the insert wall 206. The heel-side aperture 216 isalso shown, and a back side 222 of the face insert 44 is visible. Theangled segments 172 of the lattice structure 136 extend from upper andlower ends of the insert wall 206, toward the rear portion 62 of theclub head 40. A hosel bar 224 is also shown, the hosel bar 224 beingaligned with the hosel 90, but being disposed entirely within the cavity130. The hosel bar 224 is generally aligned with the hosel 90, andextends vertically between the crown 52 and the sole 54 of the body 42.One of the design elements 200 is further shown in FIG. 14 with a layerof the adhesive or bonding agent 126 disposed intermediate the designelement 200 and the body 42. Still further, circular protrusions 226 areshown extending outward from the inner surface 220 of the insert wall206. The circular protrusions 226 may be disposed along the innersurface 220 to aid with acoustics, altering the CT of the club head 40,or for another reason.

Referring now to FIG. 15 , another cross-sectional view of the club head40 is shown. The angled segments 172 of the lattice structure 136 thatextend from the inner surface 220 of the insert wall 206 are shownintersecting with other angled segments 172. Referring specifically tothe centrally located angled segments 172, these angled segments 172 areoffset from one another, such that the angled segments 172 are notdisposed entirely within the same plane. Various other segments 172,174, 176 are also offset from one another, such that intersectingsegments 172, 174, 176 are not disposed within the same plane as oneanother. Still referring to FIG. 15 , the upper inset region 144 and thelower inset region 146 are partially shown, along with the variousalignment features 156 along the alignment platform 154. A portion ofthe central alignment feature 158 is also shown in FIG. 15 . The window160 is further shown, with portions of the angled segments 172 beingvisible through the window 160.

Referring now to FIG. 16 , a cross-sectional view taken through thefasteners 192 and the weights 132, 134 is shown. Various segments 172,174, 176 are shown, which intersect at varying locations. Many of theintersection points 182 of the segments 172, 174, 176 are defined by therounds, which may define acute, obtuse, or right angles. The fasteners192 are further shown being disposed within the fastener apertures 190,and retaining the weights 132, 134 between the upper and lower retentionfeatures 166, 168. While the window 160 is shown being see-through, itis contemplated that an insert or another feature may be positionedwithin the window 160 to prevent debris from entering into the cavity130 during use of the club head 40. Still further, it is contemplatedthat a polymer or another type of filler material (not shown) may bedisposed within the head cavity 130 such that the material is disposedwithin the lattice structure 136. The material may be included to addweight or modify certain characteristics of the club head 40. In someembodiments, the material may be added within the head cavity 130 toprevent materials such as dirt or other foreign matter from becomingengaged within the head cavity 130.

Referring to FIG. 17 , a cross-sectional view taken through the centralalignment feature 158 is shown. The design feature 200 along the sole 54of the club head 40 is shown with a layer of the adhesive 126 disposedbetween the design feature 200 and the body 42. The face insert 44 isalso shown with a layer of the adhesive 126 disposed between the faceinsert 44 and the insert wall 206. One of the circular protrusions 226is also shown extending from the inner surface 220 of the insert wall206. Varying other segments 172, 174, 176 of the lattice structure 136are also shown extending across varying portions of the club head 40.The first weight 132 is visible within the background of FIG. 17 . Theupper inset region 144 and the lower inset region 146 are further shown,along with the upper inset edge 148 and the lower inset edge 152.

Now referring to FIGS. 18 and 19 , cross-sectional views of the clubhead 40 and the post-printed component 204 are shown, respectively, toillustrate contrasts between the club heads after and before postprinting processing, respectively. The various material deposits 208 arevisible in FIG. 19 , while the material deposits are shown having beenremoved, i.e., grinded down, drilled out, or otherwise machined in FIG.18 . Further, the heel-side notch 216 in FIG. 19 has become theheel-side aperture 216 in FIG. 18 , which is achieved through drilling,grinding, or another type of machining process. The shaft cavity 122 isalso shown having been drilled out or otherwise machined in FIG. 18 ,while the shaft cavity 122 is shown filled-in in FIG. 19 . Various otherdifferences are visible between the pre- and post-processing versions ofthe club head, which may be achieved through a number of manufacturingtechniques known to those skilled in the art. For example, certainsurfaces and corners are grinded down or otherwise machined to achievethe club head 40 shown in FIG. 18 .

Referring to FIG. 20 , a cross-sectional view of the club head 40 isshown that is taken through a center of the hosel 90. The hosel notches112, which do not extend all the way through the hosel 90, are shown,the hosel notches 112 taking various different forms along the hosel 90.To that end, the hosel arm 214 is shown extending centrally through acenter of the hosel 90, the hosel arm 214 defining the various hoselnotches 112 that are cutout from the hosel 90. The hosel notches 112, insome embodiments, may be disposed in a direction that is orthogonal withrespect to the orientation shown in FIG. 20 . The groove 120 thatseparates the front region 60 and the rear region 62 of the body 42 isfurther shown in FIG. 20 , the groove 120 being generally v-shaped incross-section.

Referring now to FIGS. 21 and 22 , the face insert 44 is shown ingreater detail. As noted above, the face insert 44 defines the strikingsurface 68, which includes the first surface 74, the second surface 76,the third surface 78, and the fourth surface 80. In this particularembodiment, Descending Loft Technology™ is utilized, which comprisesfour flat surfaces that are milled into the face insert 44. In apreferred embodiment, each of the surfaces 74, 76, 78, 80 descends inloft by 1° from a top of the face insert 44 to a bottom of the faceinsert 44. As a result of this configuration, when a player's shaft ispressed at impact, the ball contact will be higher on the face insert44. The face insert 44 therefore delivers consistent launch angles fromputt to putt, which can lead to more consistent and predictable rolls.

Referring now to FIG. 23 , a horizontal cross-sectional view of the clubhead 40 is shown. In this view, the hosel bar 224, the first weight 132,and the second weight 134 are shown in cross section. The fasteners 192are also shown in cross section, along with the lattice structure 136.The rear lattice row 182 and the front lattice row 180 are also shown.The front lattice row 180 and the rear lattice row 182 define aplurality of the segments 172, 174, 176, which extend in a wide range ofdirections. In some embodiments, the disposition of the one or moresegments 172, 174, 176 may be modified to change one or morecharacteristics of the club head 40, such as the CG, CT, weightdistribution, or another characteristic. Still further, in someembodiments, additional lattice rows may be added, and the segments 172,174, 176 may be disposed in alternative configurations. As provided inFIG. 23 , the lattice structure 136 is generally limited to the medialregion 86 of the club head 40, with edge portions slightly crossing overinto the heel region 88 and the toe region 84. In some embodiments, thelattice structure 136 may extend entirely across one or more of the toeregion 84, the medial region 86, and the heel region 88. The latticestructure 136 may also extend only in a region defined between the firstweight 132 and the second weight 134.

In general, the additive manufacturing principles and advantages of theputter-type club head 40 and the corresponding post-printed component204 may be applied to other types of golf club heads. For example, aniron-type golf club head may be manufactured using an additivemanufacturing technique and, in some embodiments, designed to include aninternal or an external lattice structure or portion. The incorporationof a lattice structure into an iron-type golf club head via additivemanufacturing may provide several manufacturing and performanceadvantages, in addition to enabling the design of an iron-type golf clubhead to leverage performance benefits from various iron club headdesigns.

For example, conventional iron-type golf club heads may generally bedesigned with a muscle back design, a cavity back design, or a hollowconstruction. Typically, these conventional iron designs are limited inCG movement due to their volume and manufacturing method (e.g., forging,casting, metal injection molding, machined, etc.). Certain players maybenefit from playing a mid or large volume club head design thatperforms like a low volume club head. For example, hollow constructionsare typically designed with a club face insert that may only besupported around a periphery of the face insert (e.g., the face insertis generally unsupported over the surface area that contacts a golfball). Unsupported face inserts may provide inconsistent launchconditions and greater distance variability when compared to an irondesign with a supported face (e.g., a muscle back design), but mayprovide greater distance and forgiveness. Additive manufacturing mayallow for the design of a larger volume club head, which defines ahigher MOI, with a supported face (e.g., similar to a low volume irondesign) and the ability to adjust a CG location by adjusting mass andlattice structure locations.

Referring now to FIGS. 24-27 , an iron-type golf club head 300 is shownin accordance with the present disclosure that may be formed through anadditive manufacturing process. The iron-type golf club head 300includes a body 302 that defines an external skin or shell 304 thatencloses an internal cavity 306 (see FIGS. 26 and 27 ). The externalshell 304 may be formed around an external boundary of the body 302(e.g., a boundary that is externally visible). In general, the iron-typegolf club head 300 may be formed by an additive manufacturing process todefine the appearance of a hollow construction iron design (e.g., alarger volume when compared to a muscle back design), which createsextra volume (i.e., the internal cavity 306) within the external shell304 to manipulate club head properties and/or performance. For example,the internal cavity 306 may be manipulated by adding solid material, alattice structure, a weight, leaving it hollow, or any combinationthereof to create unique CG locations and mass properties to influenceface flex and performance.

In general, the external shell 304 may form a thin border around asubstantial portion or an entirety of the body 302 to give theappearance that the iron-type golf club head 300 is solid when viewedexternally. The internal cavity 306 may be formed by a boundary definedby an inner periphery of the external shell 304.

The iron-type golf club head 300 defines a toe side 308, a heel side310, a front side 312, a top side 314, a bottom side 316, and a rearside 318. The body 302 includes a toe region 320, a medial region 322,and a heel region 324. Referring specifically to FIGS. 24 and 25 , thetoe region 320, the medial region 322, and the heel region 324 aredefined by lines or planes P1 and P2 that extend through the iron-typegolf club head 300 in a sole-topline direction 326 (e.g., a verticaldirection from the perspective of FIGS. 24 and 25 ). The toe region 320and the heel region 324 are arranged at laterally-opposing ends of thebody 302, and the medial region 322 is arranged laterally between thetoe region 320 and the heel region 324.

The front side 312 of the body 302 may define a front face 327 thatextends along the front side 312 of the body 302 from the toe region320, through the medial region 322, and into at least a portion of theheel region 324. In some embodiments, the front face 327 may define anentire front surface of the body 302 that extends laterally from the toeregion 320, through the medial region 322, and into the heel region 324to a junction between the front surface and a hosel 344 extending fromthe heel region 324. In some embodiments, a portion of the front face327 defined along the medial region 322 defines a striking face, whichmay include a plurality of laterally-extending grooves that are spacedfrom one another in the sole-topline direction 326 (see FIG. 39 ).

The iron-type golf club head 300 defines a topline 328 extendinglaterally in a heel-toe direction 330 (e.g., a horizontal direction fromthe perspective of FIGS. 24 and 25 ) along the top side 314, and a sole332 extending laterally in the heel-toe direction 330 along the bottomside 316. The toe region 320 includes a toe portion 334 of the body 302that is defined by a portion of the body 302 between a distal end of thetoe side 308 and the plane P1. In some embodiments, the plane P1 may bedefined along a lateral edge of the grooves (not shown) formed in thefront side 312 that is adjacent to the toe side 308. In someembodiments, the plane P1 may intersect the top side 314 of the toeportion 334 at a toe-topline intersection point 336 along the topline328 where the slope of a line tangent to the topline 328 isapproximately zero (e.g., a point where a line tangent to the peripheryof the top side 314 is approximately parallel to the ground at address).In these embodiments, the plane P1 may extend through the toe portion334 in the sole-topline direction 326 to a toe-sole intersection point337.

The heel region 324 includes a heel portion 338 of the body 302 that isdefined by a portion of the body 302 between a distal end of the heelside 310 and the plane P2. In some embodiments, the plane P2 may bedefined along a lateral edge of the grooves (not shown) formed in thefront side 312 that is adjacent to the heel side 310. In someembodiments, the plane P2 may intersect the top side 314 at aheel-topline inflection point 340 (e.g., a point where the periphery ofthe top side 314 transitions from concave down to concave up). In theseembodiments, the plane P2 may extend through the heel portion 338 in thesole-topline direction 326 to a heel-sole intersection point 342.

The heel portion 338 includes the hosel 344 that extends from the heelportion 338 at an angle (e.g., a lie angle formed between a planeparallel to the ground on which the club head rests at address and acenter axis defined through the hosel 344) in a direction away from thetoe portion 334. The hosel 344 defines a hosel cavity 346 (see FIG. 26 )within which a shaft (not shown) may be inserted for coupling to theiron-type golf club head 300. In some embodiments, a ferrule (not shown)may abut or be at least partially inserted into the hosel 344. In someembodiments the hosel cavity 346 may extend through at least a portionof the hosel 344.

The topline 328 may extend along an outer periphery of the top side 314of the body 302 from the heel-topline inflection point 340, along themedial region 322, to the toe-topline intersection point 336. The sole332 may extend along a periphery of the bottom side 316 of the body 302from the toe-sole intersection point 337, along the medial region 322,to the heel-sole intersection point 342.

With reference to FIGS. 26-31 , the internal cavity 306 of the body 302includes a lattice structure 348 arranged within at least a portion ofthe internal cavity 306. For example, in some embodiments, the latticestructure 348 may extend in the sole-topline direction 326 along theentire internal cavity 306 (see FIGS. 26 and 27 ). In some embodiments,the lattice structure 348 may extend in the sole-topline direction 326along a portion of the internal cavity 306. For example, the latticestructure 348 may extend from an end of the internal cavity 306 adjacentto the topline 328 to a location between the topline 328 and the sole332 (see FIGS. 28 and 29 ). Alternatively, the lattice structure 348 mayextend from an end of the internal cavity 306 adjacent to the sole 332to a location between the sole 332 and the topline 328 (see FIGS. 30 and31 ).

In some embodiments, the lattice structure 348 may extend laterally inthe heel-toe direction 330 along substantially the entire internalcavity 306. For example, the lattice structure 348 may extend laterallyin the heel-toe direction 330 from the toe region 320, through themedial region 322, and into at least a portion of the heel region 324.In some embodiments, the lattice structure 348 may extend laterally inthe heel-toe direction 330 a distance defined by a lateral extension ofthe front face 327 (e.g., the lattice structure 348 may extend the samelateral distance as the front face 327).

In general, the incorporation of the lattice structure 348 into theinternal cavity 306 defines a lower density relative to a solid material(e.g., solid metal) filling within the internal cavity 306 of the samevolume. Since the lattice structure 348 defines a lower density comparedto a solid material (e.g., solid metal) filling of the same volume, a CGvolume ratio defined as a ratio between a volume V_(L) that the latticestructure 348 occupies in the internal cavity 306 to a volume V_(S) thata solid portion 349 occupies within the internal cavity 306 may bealtered to move the CG location in the sole-topline direction 326. Inother words, an orientation of the lattice structure 348 between thetopline 328 and the sole 332 (e.g., a distance that the latticestructure 348 extends over the internal cavity 306 in the sole-toplinedirection 326) and the volume ratio may define a CG defined by the body302. The orientation of the lattice structure 348 and the volume ratiomay be altered to define a desired CG location for the iron-type golfclub head 300.

With specific reference to FIGS. 28-31 , the arrangement, dimensions,and volume of the lattice structure 348 within the internal cavity 306may be customized to define a high CG (e.g., a CG arranged closer to thetopline 328) or a low CG (e.g., a CG arranged closer to the sole 332).For example, the iron-type golf club head 300 illustrated in FIGS. 28and 29 may define a CG point 350 that is higher (e.g., closer to thetopline 328) when compared to a CG point 352 defined by the iron-typegolf club head 300 illustrated in FIGS. 30 and 31 . This is due to thedifferences in the arrangement, dimensions, and volume of the latticestructure 348 illustrated in FIGS. 28-31 . For example, arranging thelattice structure 348 adjacent to the topline 328 (see FIGS. 28 and 29 )and filling a reminder of the internal cavity 306 adjacent to the sole332 with the solid portion 349 (e.g., solid metal material that isformed layer by layer) provides more high density material adjacent tothe sole 332 and, thereby, lowers the CG of the iron-type golf club head300. Conversely, arranging the lattice structure 348 adjacent to thesole 332 (see FIGS. 30 and 31 ) and filling a reminder of the internalcavity 306 adjacent to the topline 328 with the solid portion 349provides more high density material adjacent to the topline 328 and,thereby, raises the CG of the iron-type golf club head 300.

The incorporation of the lattice structure 348 in the internal cavity306 of the iron-type golf club head 300 enables the CG location to bemanipulated to any location between a CG defined by a completely solidbody (e.g., the internal cavity 306 is completely filled with solidmaterial) and a CG define by a completely hollow body (e.g., theinternal cavity 306 is completely hollow or devoid of material). Itshould be appreciated that the volumes defined by the lattice structure348 (V_(L)) and the solid portion 349 (V_(S)) of the internal cavity 306do not need to be discretely defined along the sole-topline direction326. That is, in some embodiments, the lattice structure 348 may includeone or more solid portions 349 arranged on vertically-opposing sidesthereof. For example, the lattice structure 348 may not originate froman internal side of the external shell 304 adjacent to the top side 314or an internal side of the external shell 304 adjacent to the bottomside 316. Rather, the internal cavity 306 may include solid portions 349that extend from the top and bottom internal sides of the external shell304 that form the internal cavity 306 and the lattice structure 348 maybe arranged between the solid portions 349. Alternatively, the internalcavity 306 may include one or more lattice structure 348 that areseparated in the sole-topline direction 326 with the solid portion 349arranged therebetween.

In some embodiments, the variability and control over the CG locationprovided by the incorporation of the lattice structure 348 into theiron-type golf club head 300 may be leveraged when designing andmanufacturing a set of iron-type golf club heads. For example, a set ofirons may include long irons (e.g., 1-iron through 5-iron), mid irons(e.g., 6-iron through 9-iron), short irons (e.g., pitching wedge throughlob wedge), and it may be desirable to define varying CG locations foreach iron within a set. In some embodiments, the various types of ironswithin a set may define varying CG locations (e.g., long irons define alow CG, mid irons define a middle CG, and short irons define a high CG,or another configuration). In any case, a set of iron-type golf clubheads according to the present disclosure may include at least twoiron-type golf club heads manufactured via an additive manufacturingprocess with a lattice structure incorporated in both of the iron-typegolf club heads at varying CG volume ratios to define different CGlocations along the sole-topline direction 326 for each of the iron-typegolf club heads produced.

In some embodiments, a set of iron-type golf club heads according to thepresent disclosure may include a first golf club head and a second golfclub head. The first golf club head may define a first orientation of afirst lattice structure between a sole and a topline and a first volumeratio between a first lattice volume and a first solid volume. Thesecond golf club head may define a second orientation of a secondlattice structure between a sole and a topline and a second volume ratiobetween a second lattice volume and a second solid volume. In someembodiments, the second orientation may be different than the firstorientation to define a different CG between the first golf club headand the second golf club head. In some embodiments, the second volumeratio may be different than the first volume ratio to define a differentCG between the first golf club head and the second golf club head. Insome embodiments, the second orientation may be different than the firstorientation and the second volume ratio may be different than the firstvolume ratio to define a different CG between the first golf club headand the second golf club head.

In addition to the ability of the lattice structure 348 to manipulatethe CG location of the iron-type golf club head 300, a stiffness definedalong the external shell 304 in the regions occupied by the latticestructure 348 may be maintained, for example, similar to the stiffnesssupport provided by the solid portion 349. For example, in someembodiments, the front face 327 of the body 302 is supported by (e.g.,in engagement with) one of the lattice structure 348 and the solidportion 349 along an entire surface area thereof, which prevents localareas of non-uniform or reduced stiffness. In this way, for example, theincorporation of the lattice structure 348 into the iron-type golf clubhead 300 enables the iron-type golf club head 300 to provide theadvantages of various iron designs to a user. For example, the iron-typegolf club head 300 may provide the consistent launch conditions anddistance variability of a low volume (e.g., muscle back) iron design andthe increased MOI of a mid or high volume iron design.

In some embodiments, the iron-type golf club head 300 may be designed toprovide enhanced distance (e.g., a utility iron) and may include alattice structure that is attached to the body but does not support thefront face or a face insert coupled to the body. For example, withreference to FIGS. 32 and 33 , the iron-type golf club head 300 mayinclude a face insert 354 that is coupled to the front side 312 of thebody 302 and attached (e.g., via welding) around a periphery of thefront side 312. When the face insert 354 is coupled to the body 302, theinternal cavity 306 may be enclosed by the external shell 304 and theface insert 354, and the lattice structure 348 may be enclosed withinthe internal cavity 306.

In the illustrated embodiment, the lattice structure 348 extends fromthe internal surfaces of the external shell 304. For example, thelattice structure 348 may be attached to or supported by the internalsurfaces of the external shell 304 on the body 302 adjacent to the toeside 308, the heel side 310, the top side 314, the bottom side 316, andthe rear side 318. The lattice structure 348 may be interrupted by thesolid portion 349 that, in the illustrated embodiment, extends along thebottom side 316 from the toe region 320 to a location between the toeregion 320 and the heel region 324 (see FIG. 32 ). When the face insert354 is attached to the body 302, a gap 356 may be formed between atermination plane T defined by the lattice structure 348 (e.g., a planegenerally parallel to the face insert 354 along which the latticestructure 348 terminates) and the face insert 354. In other words, thelattice structure 348 may be set back from the face insert 354 leavingthe face insert 354 unsupported by the lattice structure 348.

The design and construction of the iron-type golf club head 300illustrated in FIGS. 32 and 33 provides support for the face insert 354only around the periphery thereof and creates a stiffer body structure,which allows the face insert 354 to be thinner, thereby enhancingperformance (e.g., increased distance). In some embodiments, the faceinsert 354 may be manufactured via an additive manufacturing process. Asdescribed herein, in some embodiments, an orientation of a golf clubhead relative to a build plane during an additive manufacturing processmay improve the quality and performance of the green part of the finalpost-sintering product. In configurations where a face insert is notplanar and includes, for example, a portion of a sole integrated with astriking surface (i.e., an L-cup face insert), it may be beneficial toorient the face insert such that the front face or striking surface isrotationally offset from the build plane. In this way, for example, thelayer lines formed during the additive manufacturing process may notpass through the edge where the front face transitions to the sole(e.g., a leading edge). That is, if the face insert were manufacturedwith the front face oriented parallel to the build plane, a layer linemay pass through the leading edge of the face insert, which may causedefects in the green part and/or the post-sintered part. This is avoidedby printing the face insert with the front face rotationally offsetrelative to the build plane. In addition, the rotational orientation ofthe face insert relative to the build plane may be tailored to maximizeefficiency of the additive manufacturing process (i.e., arrange as manyface inserts within a given build area to manufacture as many faceinserts as possible during a build).

With reference to FIGS. 34 and 35 , in some embodiments, an aperture 358may be formed, for example, via additive manufacturing, that extendslaterally into and through the solid portion 349. The aperture 358 mayextend laterally from the toe side 308 of the solid portion 349 to alocation between the toe side 308 and an end of the solid portion 349.In some embodiments, the aperture 358 may be filled with a weight bar360 (e.g., tungsten). The incorporation of the weight bar 360 may aid inlowering the CG location of the iron-type golf club head 300 along thesole-topline direction 326.

In some embodiments, the iron-type golf club head 300 may bemanufactured to enable the weight bar 360 to be attached or securedwithin the aperture 358 via a sintering process. For example, the weightbar 360 may be manufactured with dimensions that are a predeterminedpercentage larger than the factory finish dimensions. In someembodiments, the predetermined percentage may be about 10%, or about15%, or about 20%, or about 25%, or about 30% larger than the factoryfinish dimensions of the iron-type golf club head. In some embodiments,the predetermined percentage may be between about 10% and about 30%, orbetween about 15% to about 25%, or between about 16% and about 20%. Insome embodiments, the weight bar 360 may be manufactured via an additivemanufacturing process. In some embodiments, the weight bar 360 may beformed by a metal injection molding process. In any case, once theweight bar 360 is initially manufactured with dimensions that are thepredetermined percentage larger than the factory finish dimensions, theweight bar 360 may go through a sintering process. During the sinteringprocess, the weight bar 360 may shrink to at least one of the factoryfinish dimensions. For example, the weight bar 360 may shrink to afactory finish diameter, but may still define a length that is longerthan a factory finish length to enable the weight bar 360 to be cut tolength and conform to the outer profile of the body 302 duringpost-processing.

Similar to the weight bar 360, the body 302 of the iron-type golf clubhead 300 may be manufactured with dimensions that are a predeterminedbody percentage larger than the factory finish dimensions. In someembodiments, the body 302 may be manufacturing via a binder jettingprocess and the predetermined body percentage may be about 10%, or about15%, or about 20%, or about 25%, or about 30% larger than the factoryfinish dimensions of the iron-type golf club head. In some embodiments,the predetermined percentage may be between about 10% and about 30%, orbetween about 15% to about 25%, or between about 16% and about 20%. Oncethe body 302 is initially manufactured with dimensions that are largerthan the factory finish dimensions, the body 302 may go through asintering process. Prior to the sintering process, the post-sinteredweight bar 360 may be inserted into the body 302 at the predefinedlocation (e.g., the aperture 358). The sintering process may shrink thebody 302 to the factor finish dimensions. During the sintering process,the body 302 may shrink around the weight bar 360 and form aninterference fit between the body 302 and the weight bar 360, therebysecuring the weight bar 360 within the body 302 without requiring anysecondary adhesion techniques (e.g., welding, adhesive, etc.).

By first sintering the weight bar 360 and then sintering the body 302with the post-sintered weight bar 360 installed within the body 302, theiron-type golf club head 300 may naturally form an interference fitbetween the body 302 and the weight bar 360, which secures the weightbar 360 within the body 302. For example, once the weight bar 360 issintered, it may be substantially prevented from further shrinkage,which allows the secondary sintering of the iron-type golf club head 300to shrink around the weight bar 360 and form a natural interference fittherebetween. In addition, this manufacturing process avoids issues thatmay arise due to sintering a golf club head that includes metals withdifferent densities. For example, if the weight bar 360 and the body 302were sintered for the first time together, the weight bar 360 wouldshrink more than the body 302 due to increased density relative to thebody 302. As such, the weight bar 360 may not fit within the body 302post-sintering and add inefficiencies to the manufacture of theiron-type golf club head 300. Further, the staged sintering processavoids issues that arise due to different metals requiring differentsintering temperatures. In general, this staged sintering process may beused to couple a weight bar to a body of a golf club head as long as theweight bar and a cavity within which the weight bar is to be arrangeddefine a similar or the same shape.

In some embodiments, rather than a weight insert, the density of a golfclub head according to the present disclosure may be controlled by theadditive manufacturing process. For example, in a DMLS process, a speedat which the laser translates over a component and creates a layer isproportional to a density of the metal formed. As such, a speed at whichthe laser translates over selective portions when manufacturing a golfclub head layer by layer may be controlled to define a desired densityprofile over the entire volume of the golf club head. In the embodimentof FIGS. 34 and 35 , the laser may be slowed down when traversing overportions of the iron-type golf club head 300 within the solid portion349. In this way, for example, the solid portion 349 may include atleast a portion thereof that defines a higher density and aids inlowering the CG of the iron-type golf club head 300, similar to theweight bar 360.

In some embodiments, the iron-type golf club head 300 may be designed toincorporate a lattice structure that is attached only behind the frontface and does not support a remainder of the body. With reference toFIG. 36 , the iron-type golf club head 300 may include the latticestructure 348 arranged on a rear surface of the front face 327. Athickness (e.g., a distance that the lattice structure 348 extends awayfrom the front face 327 along a direction parallel to a normal definedby the front face 327) defined by the lattice structure 348 may bedimensioned such that lattice structure 348 only engages the front face327 and the remainder of the body 302 may be unsupported by the latticestructure 348. In other words, a gap 362 may be arranged between thelattice structure 348 and a rear portion 364 of the body 302 (e.g., aportion of the body 302 arranged reward of the front face 327), whichmay be fabricated from solid material (e.g., solid metal that is formedlayer by layer), along an entire area defined by the front face 327. Inthis way, for example, the stiffness of the front face 327 may beincreased (e.g., when compared to a front face/face insert without alattice structure connected thereto). In some embodiments, for example,the lattice structure 348 may be arranged over a portion of the rearsurface of the front face 327, rather than an entirety of the rearsurface.

The increased stiffness provided by the lattice structure 348 beingattached to the front face 327 may provide more consistent launchconditions and improved distance variability similar to a low volume(e.g., muscle back) iron design. In addition, a shape, size, and massdistribution in the rear portion 364 may be easily tailored orcustomized via additive manufacturing to allow for variations in CGlocation, MOI, etc.

As described herein, the size, shape, volume, and arrangement of thelattice structure 348 within the body 302 of the iron-type golf clubhead 300 may be controlled or designed to provide stiffness to selectiveportions of the body 302, the front face 327, and/or the face insert354. With the lattice structure 348 acting as a local stiffeningstructure, the location of the lattice structure 348 within the body 302may directly impact performance of the iron-type golf club head 300(e.g., sound, feel, ball speed, distance variability, launch conditions,etc.).

In some embodiments, the stiffness differences in the front face 327provided by the support or lack thereof by the lattice structure 348 maybe leveraged to produce a set of iron-type golf club heads with varyingface stiffness. Similar to conventional iron-type golf club sets thattransition from cavity back/hollow construction to muscle back design asthey transition from long irons to short irons, the design of theiron-type golf club head 300 may be varied using additive manufacturingto provide varying performance characteristics as the iron-type golfclub heads transition from long irons to short irons. For example, a setof iron-type golf club heads according to the present disclosure mayinclude at least two iron-type golf club heads that transition from afront face or face insert that is not supported by a lattice structureto a front face or face insert that is at least partially supported by alattice structure to leverage the performance benefits of thesedifferent designs described herein in a single set of iron-type golfclub heads.

As described herein, there are several performance and design advantagesto incorporating a lattice structure into an iron-type golf club head,or another type of golf club head, via additive manufacturing. In orderto effectively manufacture the iron-type golf club head according to thepresent disclosure certain design aspects should be considered. Forexample, many additive manufacturing processes utilize a metal powderbed to produce components layer by layer, as described herein. Similarto the putter-type golf club head 40, iron-type golf club heads may berequired to be de-caked of residual metal powder that remains after theinitial scavenging of the printed component from the powder bed.

In general, an iron-type golf club head according to the presentdisclosure may define a flow path that extends through the body to allowa fluid (e.g., gas) to be forced through or sucked out of the body. Insome embodiments, the flow path may be formed via apertures or slotsformed in the body and may extend through a lattice structure. Referringto FIGS. 37 and 38 , in some embodiments, the body 302 may define a flowpath 366 that extends along the internal cavity 306 and the hosel cavity346. Specifically, the lattice structure 348 may be formed by aplurality of segments that form a plurality of cutouts, or absences ofmaterial, between the plurality of segments. In this way, for example,fluid flow may occur through the lattice structure 348. In someembodiments, the lattice structure 348 may include shapes or surfacesthat define one or more cutouts, or absences of material, to enablefluid flow therethrough.

The internal cavity 306, including the lattice structure 348 formedtherein, may be in fluid communication with the hosel cavity 346 and atleast one other aperture or slot formed in the body 302. For example,with specific reference to FIG. 38 , a slot 368 may be formed in therear side 318 of the body 302 that extends laterally across the body302. In this embodiment, the flow path 366 may extend from the hoselcavity 346, along the lattice structure 348, and through the slot 368 todefine a flow path that extends through the body 302. In this way, forexample, pressurized fluid (e.g., gas), a vacuum, a brush, a tool, orgravity may be applied to the flow path 366 to aid in removing powderedmetal and excess material from the additive manufacturing process (i.e.,de-caking).

In some embodiments, the iron-type golf club head 300 may not includethe slot 368 and, rather, may include an aperture (not shown) formed,for example, in the toe portion 334. The aperture (not shown) formed inthe toe portion 334 may extend into the internal cavity 306 to providefluid communication with the lattice structure 348. The aperture (notshown) may be utilized after manufacturing the body 302 via an additivemanufacturing process to provide compressed fluid (e.g., gas) or avacuum to the flow path 366 to aid in removing powdered metal and excessmaterial. After the leveraging the flow path 366 for the de-cakingprocess, the aperture may be plugged, for example, by a screw or a plugto prevent debris from entering the internal cavity 306 during use.

In some applications, the arrangement and number of openings that form aflow path may be varied dependent on the type additive manufacturingprocess being used to form a golf club head. For example, in an additivemanufacturing process where the manufactured part defines a density thatis close to a solid metal part (e.g., SLM, DMLS, etc.), the number ofopenings in a flow path may be reduced when compared to an additivemanufacturing process where the manufactured part defines a lowerdensity and higher porosity (e.g., binder jetting). The lower densityand high porosity defined by the green part after a binder jettingprocess may be susceptible to damage if high pressure fluid is used toremove excess metal powder from the part. For example, blowing the metalpowder over the green part after a binder jetting process may act like asand blaster and affect the quality of the green part. For thesereasons, it may be beneficial to include at least two openings in a flowpath for a golf club head manufactured using, for example, a binderjetting process. In any case, a golf club head manufactured using anadditive manufacturing process may be designed to include at least oneopening into a flow path from with excess material may be removed fromthe manufactured part.

As described herein, an iron-type golf club head according to thepresent disclosure may be manufactured using a binder jetting process,an SLM, a DMLS additive manufacturing process, or another direct lasermetal melting process. In DMLS, for example, support structures areleveraged to attach the component being manufactured to a build plateand to protect against warping/distortion that may occur due to the hightemperatures utilized during the additive manufacturing process. In someinstances, when a lattice structure is created by an additivemanufacturing process (e.g., DMLS), it may need support structuresduring printing. It is advantageous to avoid creating support structuresbecause they are difficult to remove, especially from internal cavitiesand overhangs. The necessity for support structures is dependent on theadditive manufacturing process, orientation of the lattice structure,and design of the lattice within the club head.

In some embodiments, a golf club head manufactured using an additivemanufacturing process according to the present disclosure may include alattice structure that is self-supporting and does not require internalsupports to be created. In general, print orientation (i.e., theorientation of a build plane along which the golf club head is formedlayer by layer) relative to lattice structure design can ensure that thelattice structure is self-supporting.

Referring to FIGS. 39 and 40 , a second plane or build plane B may bedefined as a plane along which the iron-type golf club head 300 isprinted layer by layer during the additive manufacturing process. In theillustrated embodiment, the build plane B is rotationally offset from afirst plane or ground plane G defined by the body 302 and that isarranged parallel to the ground on which the iron-type golf club head300 may be placed at address. As described herein, when manufacturing agolf club head via an additive manufacturing process, it is beneficialto ensure that the layer lines created during the additive manufacturingprocess avoid sharp surface interfaces (e.g., corners, edges, etc.) thatfall along layer line edges. To leverage the benefits of avoiding sharpsurface interfaces that fall along layer line edges, the build plane Bmay be rotationally offset from the ground plane G, when viewed from thetoe side 308 (see FIG. 39 ) or the heel side 310, which results in theiron-type golf club head 300 being be printed layer by layer at an anglethat is offset by about 30 degrees with respect to the ground plane G(e.g., 30 degrees clockwise from the perspective of FIG. 39 ). In someembodiments, the iron-type golf club head 300 may be printed along abuild plane B that is offset at an angle of between about 0 degrees andabout 175 degrees, or between about 5 degrees and 160 degrees, orbetween about 5 and about 140 degrees, or between about 5 degrees and120 degrees, or between about 5 degrees and 90 degrees, or 5 degrees andabout 60 degrees, or between about 10 degrees and about 50 degrees, orbetween about 20 degrees and about 40 degrees with respect to the groundplane G.

The lattice structure 348 may define one or more lattice build anglesrelative to the build plane B. Each of the lattice build angles isdefined along a common plane defined by the lattice structure 348. Forexample, the lattice structure 348 may be formed by a plurality ofsegments 370 that extend from an internal boundary of the internalcavity 306 to either another internal boundary or the solid portion 349.In the illustrated embodiment, the internal cavity 306 may be formed byan internal sole surface 372, an internal rear surface 374, an internalfront surface 376, and an internal top surface 378. The internal topsurface 378 is formed by the interface between the solid portion 349 andthe lattice structure 348.

In the illustrated embodiment, the lattice structure 348 defines aplurality of planes along which the plurality of segments 370 extend.With specific reference to FIG. 39 , the lattice structure 348 defines alattice plane L1 that forms a lattice build angle A1 with respect to thebuild plane B, and a lattice plane L2 that forms a lattice build angleA2 with respect to the build plane B. Each of the lattice planes L1, L2is formed by a portion of the plurality of segments 370 that are alignedand oriented at the respective lattice build angle A1, A2 relative tothe build plane B. The lattice structure 348 includes a plurality ofportions that align with the lattice planes L1, L2, which are spacedfrom one another a distance that is governed by the length andorientation of the plurality of segments 370 within the latticestructure 348.

With specific reference to FIG. 40 , the lattice structure 348 defines alattice plane L3 that forms a lattice build angle A3 with respect to thebuild plane B, and a lattice plane L4 that forms a lattice build angleA4 with respect to the build plane B. Each of the lattice planes L2, L3is formed by a portion of the plurality of segments 370 that are alignedand oriented at the respective lattice build angle A3, A4 relative tothe build plane B. The lattice structure 348 includes a plurality ofportions that align with the lattice planes L3, L4, which are spacedfrom one another a distance that is governed by the length andorientation of the plurality of segments 370 within the latticestructure 348. In general, the sequential spacing and intersectionbetween each of the lattice planes L1, L2, L3, L4 forms the geometry ofthe lattice structure 348.

Through testing, it has been determined that when the build plane B isoriented parallel to a normal extending from the front face 327, thelattice structure 348 is self-supporting with lattice build angles A1,A2, A3, A4 that are each greater than or equal to 30 degrees. That is,if each of the lattice build angles A1, A2, A3, A4 is greater than orequal to 30 degrees, the lattice structure 348 may be additivelymanufactured without any additional support structures, for example,during DMLS. In this way, for example, the need to remove supportstructures on the lattice structure 348 during the post-processingstages may not be required, which significantly improves manufacturingefficiency, costs, and time.

In the illustrated embodiment, each of the lattice planes L1, L2, L3, L4extend in varying directions and form a plurality of intersection points380 where one or more of the plurality of segments 370 that form thelattice planes L1, L2, L3, L4 intersect. In the illustrated embodiment,each of the intersection points 380 may be formed by the intersection ofsix of the segments 370 extending from the intersection point 380 in adifferent direction (see FIG. 41 ), except at locations where theintersection point 380 is interrupted by one or more of the internalsole surface 372, the internal rear surface 374, the internal frontsurface 376, and the internal top surface 378 (or another surface inengagement with the lattice structure 348), or a termination plane alongwhich the lattice structure 348 terminates prior to engaging a surface(see FIG. 33 ).

With specific reference to FIG. 41 , in one embodiment, the latticestructure 348 may define a unit cell 382 that is formed by a cutout, airspace, or absence of material defined between interconnectedintersection points 380 that occur along a common plane. For example, inthe illustrated embodiment, the lattice structure 348 may definesquare-, rectangular-, or diamond-shaped unit cells 382. This geometrydefined by the unit cells 382 may be similar to the lattice structure348 illustrated in FIGS. 26-40 . However, a lattice structure accordingto the present disclosure is not limited to this shape of unit cell andalternative geometries may be utilized. For example, as describedherein, the segments 172, 174, 176 of the lattice structure 136 definegenerally triangular-shaped cutouts or air spaces. Alternatively oradditionally, in some embodiments, at least a portion of the unit cellsin a lattice structure according to the present disclosure may define apentagonal shape, a hexagonal shape, or any other polygonal shape.

In some embodiments, a unit cell defined by a lattice structureaccording to the present disclosure can be formed by interconnectedshapes (e.g., ovals, circles, or another geometric shape) with varyingorientation to form a repeated pattern, or unit cell. In someembodiments, a lattice structure according to the present disclosure maybe formed by a differential geometry structure. For example, a latticestructure according to the present disclosure may be formed by a gyroidstructure that includes a plurality of interconnected, periodic minimalsurfaces. The gyroid structure may define a unit cell that is repeatedin a pattern over a desired volume to form a lattice structure accordingto the present disclosure. In general, the use of a differentialgeometry structure (e.g., a gyroid) may reduce stress concentrationsformed along the lattice structure due to the reduction in sharp edgesformed on the lattice structure, which may provide similar advantages asadding curvature, described herein with reference to the latticestructure 136. In some embodiments, a lattice structure according to thepresent disclosure may define a tublane structure or a plate-latticestructure.

Regardless of the design and properties of the lattice structure, a golfclub head according to the present disclosure may be manufactured viaadditive manufacturing to include a lattice structure formed integrallywith at least a portion of a body, a front face, and/or a face insert ofthe golf club head. During manufacture, when the build plane is orientedparallel to the front face normal, each portion of the lattice structuremay be printed at an angle greater than or equal degrees relative to thebuild plane to ensure that the lattice structure is self-supporting anddoes not require support structures.

In some embodiments, a lattice structure according to the presentdisclosure may define a hybrid or variable structure that varies in oneor more of unit cell type, unit cell geometry, unit cell size, segmentlength, segment, thickness, segment volume, and unit cell density at oneor more locations along the lattice structure. For example, inembodiments of the iron-type golf club head 300 where the latticestructure 348 is connected to the front face 327, the lattice structure348 may be varied behind the front face 327 to improve or maximize ballspeed over the front face 327, more specific to where players actuallyimpact the golf ball (e.g., lower (closer to the sole) than a facecenter point). For example, the lattice structure 348 may vary in athickness, size, and/or shape of the segments 370, a density of the unitcells 382, and/or a shape or type of the unit cells 382 at variouslocations behind the front face 327.

As described herein, adding curvature or removing sharp edges withingeometry that is formed through additive manufacturing solves severalissues, including: helping with de-caking (e.g., helps against greenpart destruction when blowing air against a lattice structure), reducingsintering drag, and avoiding stress concentrations in a latticestructure. In the embodiments where a lattice structure according to thepresent disclosure is formed via a plurality of segments, theintersection points may be curved at each intersection between thesegments at the intersection point. For example, FIG. 42 illustrates anembodiment of an intersection point 380 taken along a cross-sectionalplane. As illustrated in FIG. 42 , the lattice structure 348 may definerounded edges at each intersection between the segments 370 forming theintersection point 380. That is, the intersecting edge formed betweeneach of the intersecting segments 370 may be rounded to define acurvature or a radius of curvature, rather than culminating at a point.In addition to the intersection points 380, each edge of the segments370 formed in the lattice structure 348 may define a rounded or curvededge.

In general, a lattice structure according to the present disclosure maydefine rounded or curved edges along, for example, edges of intersectionpoints, edges of segments forming the lattice structure, and any otheredges formed along the lattice structure to provide the manufacturingand performance benefits described herein.

In the embodiments of FIGS. 26-40 , the lattice structure 348 isarranged internally with respect to the body 302 (e.g., at leastpartially within the internal cavity 306). In some embodiments, a golfclub head may be designed to include an externally accessible/visiblelattice structure. For example, a golf club head according to thepresent disclosure may include at least one external face that is formedat least partially by a lattice structure. As described herein, removingresidual metal powder may be required following the manufacture of agolf club head via an additive manufacturing process. In someembodiments, a golf club head according to the present disclosure mayinclude apertures and/or define a flow path to enable the removal ofexcess metal powder. Another solution to aiding in removal of metalpowder from a 3D printed golf club head may be to arrange the latticestructure such that it is externally accessible/visible. In someembodiments, a depth that an externally-facing lattice structure extendsinto a body of the golf club head and/or a unit cell size (e.g., volumeor surface area) of the lattice structure may be limited to ensureefficient de-caking of residual metal powder present after manufacturingthe golf club head via an additive manufacturing process.

Referring to FIGS. 43 and 44 , an iron-type golf club head 400 is shownin accordance with the present disclosure that may be formed through anadditive manufacturing process. The iron-type golf club head 400includes a body 402 and an externally-facing lattice structure 404formed on the body 402. In general, the lattice structure 404 may beformed along a portion of an externally-facing face or surface of thebody 402 in place of solid material, which reduces a weight of theiron-type golf club head 400 and maintains stiffness (e.g., similar tothe stiffness provided by solid material).

The iron-type golf club head 400 defines a toe side 408, a heel side410, a front side 412, a top side 414, a bottom side 416, and a rearside 418. The body 402 includes a toe region 420, a medial region 422,and a heel region 424. The toe region 420, the medial region 422, andthe heel region 424 are defined by lines or planes P1 and P2 that extendthrough the iron-type golf club head 400 in a sole-topline direction 426(e.g., a vertical direction from the perspective of FIG. 43 ). The toeregion 420 and the heel region 424 are arranged at laterally-opposingends of the body 402, and the medial region 422 is arranged laterallybetween the toe region 420 and the heel region 424.

The front side 412 of the body 402 may define a front face 427 thatextends along the front side 412 of the body 402 from the toe region420, through the medial region 422, and into to at least a portion ofthe heel region 424. In some embodiments, the front face 427 may definean entire front surface of the body 402 that extends laterally from thetoe region 420, through the medial region 422, and into the heel region424 to a junction between the front surface and a hosel 444 extendingfrom the heel region 424. In some embodiments, a portion of the frontface 427 defined along the medial region 422 defines a striking face,which may include a plurality of laterally-extending grooves (not shown)that are spaced from one another in the sole-topline direction 426.

The iron-type golf club head 400 defines a topline 428 extendinglaterally in a heel-toe direction 430 (e.g., a horizontal direction fromthe perspective of FIG. 43 ) along the top side 414, and a sole 432extending laterally in the heel-toe direction 430 along the bottom side416. The toe region 420 includes a toe portion 434 of the body 402 thatis defined by a portion of the body 402 between a distal end of the toeside 408 and the plane P1. In some embodiments, the plane P1 may bedefined along a lateral edge of the grooves (not shown) formed in thefront side 412 that is adjacent to the toe side 408. In someembodiments, the plane P1 may intersect the top side 414 of the toeportion 434 at a toe-topline intersection point 436 along the topline428 where the slope of a line tangent to the topline 428 isapproximately zero (e.g., a point where a line tangent to the peripheryof the top side 414 is approximately parallel to the ground at address).In these embodiments, the plane P1 may extend through the toe portion434 in the sole-topline direction 426 to a toe-sole intersection point437.

The heel region 424 includes a heel portion 438 of the body 402 that isdefined by a portion of the body 402 between a distal end of the heelside 410 and the plane P2. In some embodiments, the plane P2 may bedefined along a lateral edge of the grooves (not shown) formed in thefront side 412 that is adjacent to the heel side 410. In someembodiments, the plane P2 may intersect the top side 414 at aheel-topline inflection point 440 (e.g., a point where the periphery ofthe top side 414 transitions from concave down to concave up). In theseembodiments, the plane P2 may extend through the heel portion 438 in thesole-topline direction 426 to a heel-sole intersection point 442.

The heel portion 438 includes the hosel 444 that extends from the heelportion 438 at an angle (e.g., a lie angle formed between a planeparallel to the ground on which the club head rests at address and acenter axis defined through the hosel 444) in a direction away from thetoe portion 434. The hosel 444 defines a hosel cavity (not shown) withinwhich a shaft (not shown) may be inserted for coupling to the iron-typegolf club head 400. In some embodiments, a ferrule (not shown) may abutor be at least partially inserted into the hosel 444.

The topline 428 may extend along an outer periphery of the top side 414from the heel-topline inflection point 440, along the medial region 422,to the toe-topline intersection point 436. The sole 432 may extend alonga periphery of the bottom side 416 from the toe-sole intersection point437, along the medial region 422, to the heel-sole intersection point442.

The lattice structure 404 of the iron-type golf club head 400 may bedesigned and manufactured with similar properties and characteristics asthe lattice structures disclosed herein. In the illustrated embodiment,the lattice structure 404 may define at least a portion of a rear face446 of the body 402. The rear face 446 may extend over at least aportion of the rear side 418 of the iron-type golf club head 400. Forexample, the lattice structure 404 may extend laterally (e.g., in theheel-toe direction 430) over the medial region 422 and at least aportion of each of the toe region 420 and the heel region 424. Thelattice structure 404 may extend along the sole-topline direction 426between a rear-topline edge 448 and a rear-sole edge 450.

Referring specifically to FIG. 44 , the lattice structure 404 may definean external border 452 of the body 402 along the rear face 446. In someembodiments, the external border 452 may define an externally-facingborder of the lattice structure 404 (e.g., a border of the latticestructure 404 that is externally visible/accessible). The latticestructure 404 may define a thickness 454 that the lattice structure 404extends into the body 402, for example, in a direction arrangedgenerally normal to a rear surface 455 defined by the body 402. In someembodiments, the thickness 454 may be about 5 millimeters. In someembodiments, the thickness 454 may be between about 4 millimeters andabout 6 millimeters, or between about 3 millimeters and about 7millimeters. In some embodiments, the thickness 454 may be less than orequal to about 5 millimeters.

In some embodiments, the thickness 454 defined by the lattice structure404, in combination with the lattice structure 404 defining the externalborder 452 of the body 402, may enable the lattice structure 404 to beeasily de-caked after printing of the iron-type golf club head 400. Inthe illustrated embodiment, the lattice structure 404 may include unitcells that define a generally triangular shape. In some embodiments, thelattice structure 404 may define unit cells of any shape or designaccording to the present disclosure. In some embodiments, a size andshape of the unit cells defined by the lattice structure 404 also becustomized to ensure that the de-caking process occurs efficiently.

Referring to FIG. 45 , after the iron-type golf club head 400 ismanufactured via an additive manufacturing process, the excess metalpowder may be easily removed from the externally-accessible latticestructure 404, and the lattice structure 404 may be filled with a fillermaterial 456. In some embodiments, the filler material 456 may be alight weight (e.g., low density) epoxy or resin. In some embodiments,the filler material 456 may by substantially transparent or translucent.Filling the lattice structure 404 with the filler material 456efficiently prevents debris from collecting in the lattice structure 404and, in some embodiments, may maintain the external visibility of atleast the external border 452 of the lattice structure 404.

As described herein, incorporating a lattice structure into a golf clubhead provides several manufacturing, performance, and customizableadvantages. In some embodiments, a lattice structure may be utilized toefficiently distribute the mass throughout a golf club head. Forexample, in conventional golf club heads, solid material present above ahorizontal plane (e.g., a plane that extends in the heel-toe direction)defined by the CG is inefficient, since it limits movement of the CG. Insome embodiments, a golf club head according to the present disclosuremay replace the solid material rearward of the front face and above a CGplane defined by the golf club head with a lattice structure. In thisway, the stiffness provided by the solid material may be maintained bythe lattice structure, and the replacement of the solid material withthe lattice structure reduces a density in the replaced areas, whichallows the saved mass to be used elsewhere on the golf club head toimprove performance.

Referring to FIG. 46 , an iron-type golf club head 500 is shown inaccordance with the present disclosure. The iron-type golf club head 500may define a cavity back design and may be fabricated from solidmaterial (e.g., solid metal). The iron-type golf club head 500 defines asolid CG plane C (i.e., a plane that extends in a heel-toe directionthat aligns with a CG defined by a solid configuration of the iron-typegolf club head 500) that extends laterally across a body 502 of theiron-type golf club head 500. According to embodiments of the presentinvention, the solid material arranged rearward of a front face (e.g., astriking face) and above (e.g., upward from the perspective of FIG. 46 )the solid CG plane C on the body 502 of the iron-type golf club head 500may be replaced by a lattice structure (see FIG. 47 ). In someembodiments, the solid CG plane C may be defined as a plane extendingparallel to the ground plane G at a location defined by the CG of thebody 502 when the body 502 is fabricated from solid material.

Referring now to FIGS. 47-50 , the iron-type golf club head 500 mayinclude an externally accessible/visible lattice structure 504. Theiron-type golf club head 500 defines a toe side 508, a heel side 510, afront side 512, a top side 514, a bottom side 516, and a rear side 518.The body 502 includes a toe region 520, a medial region 522, and a heelregion 524. The toe region 520, the medial region 522, and the heelregion 524 are defined by lines or planes P1 and P2 that extend throughthe iron-type golf club head 500 in a sole-topline direction 526 (e.g.,a vertical direction from the perspective of FIG. 47 ). The toe region520 and the heel region 524 are arranged at laterally-opposing ends ofthe body 502, and the medial region 522 is arranged laterally betweenthe toe region 520 and the heel region 524.

The front side 512 of the body may define a front face 527 that extendsalong the front side 512 of the body 502 from the toe region 520,through the medial region 522, and into to at least a portion of theheel region 524. In some embodiments, the front face 527 may define anentire front surface of the body 502 that extends laterally from the toeregion 520, through the medial region 522, and into the heel region 524to a junction between the front surface and a hosel 544 extending fromthe heel region 524. In some embodiments, a portion of the front face527 defined along the medial region 522 defines a striking face, whichmay include a plurality of laterally-extending grooves (not shown) thatare spaced from one another in the sole-topline direction 526 (see FIG.50 ).

The iron-type golf club head 500 defines a topline 528 extendinglaterally in a heel-toe direction 530 (e.g., a horizontal direction fromthe perspective of FIG. 47 ) along the top side 514, and a sole 532extending laterally in the heel-toe direction 530 along the bottom side516. The toe region 520 includes a toe portion 534 of the body 502 thatis defined by a portion of the body 502 between a distal end of the toeside 508 and the plane P1. In some embodiments, the plane P1 may bedefined along a lateral edge of the grooves (not shown) formed in thefront side 512 that is adjacent to the toe side 508. In someembodiments, the plane P1 may intersect the top side 514 of the toeportion 534 at a toe-topline intersection point 536 along the topline528 where the slope of a line tangent to the topline 528 isapproximately zero (e.g., a point where a line tangent to the peripheryof the top side 514 is approximately parallel to the ground at address).In these embodiments, the plane P1 may extend through the toe portion534 in the sole-topline direction 526 to a toe-sole intersection point537.

The heel region 524 includes a heel portion 538 of the body 502 that isdefined by a portion of the body 502 between a distal end of the heelside 510 and the plane P2. In some embodiments, the plane P2 may bedefined along a lateral edge of the grooves (not shown) formed in thefront side 512 that is adjacent to the heel side 510. In someembodiments, the plane P2 may intersect the top side 514 at aheel-topline inflection point 540 (e.g., a point where the periphery ofthe top side 514 transitions from concave down to concave up). In theseembodiments, the plane P2 may extend through the heel portion 538 in thesole-topline direction 526 to a heel-sole intersection point 542.

The heel portion 538 includes the hosel 544 that extends from the heelportion 538 at an angle (e.g., a lie angle formed between a planeparallel to the ground on which the club head rests at address and acenter axis defined through the hosel 544) in a direction away from thetoe portion 534. The hosel 544 defines a hosel cavity (not shown) withinwhich a shaft (not shown) may be inserted for coupling to the iron-typegolf club head 500. In some embodiments, a ferrule (not shown) may abutor be at least partially inserted into the hosel 544.

The topline 528 may extend along an outer periphery of the top side 514from the heel-topline inflection point 540, along the medial region 522,to the toe-topline intersection point 536. The sole 532 may extend alonga periphery of the bottom side 516 from the toe-sole intersection point537, along the medial region 522, to the heel-sole intersection point542.

With specific reference to FIGS. 47-49 , the lattice structure 504 ofthe iron-type golf club head 500 may be designed and manufactured withsimilar properties and characteristics as the lattice structuresdisclosed herein. In the illustrated embodiment, the lattice structure504 may include unit cells that define a generally triangular shape. Insome embodiments, the lattice structure 504 may define unit cells of anyshape or design according to the present disclosure.

The lattice structure 504 extends over a portion of the body 502 that isarranged above the solid CG plane C (e.g., in a direction from the sole532 toward the topline 528) and rearward (e.g., in a direction from thefront side 512 toward the rear side 518, or to the left from theperspective of FIG. 49 ) of the front face 527. For example, the rearsurface 546 of the front face 527 may extend along a plane R at an anglerelative to the sole-topline direction 526, which is defined by the loftof the iron-type golf club head 500. The plane R along which the rearsurface 546 extends may intersect with the solid CG plane C and theplane R and the solid CG plane C may define the boundaries of thelattice structure 504.

By replacing solid material with the lattice structure 504, the densitydefined by the body 502 in these regions may be locally reduced and thestiffness previously provided by the solid material may be maintained.In this way, for example, the CG of the iron-type golf club head 500 maybe lowered (e.g., moved in a direction toward the sole 532) compared toa golf club head made from solid material (i.e., relative to the solidCG plane C). For example, a CG volume ratio defined as a ratio between avolume V_(L) that the lattice structure 504 occupies to a volume V_(S)that solid material occupies may be a factor in defining a CG locationin the sole-topline direction 526.

In addition, the mass removed by the lattice structure 504 may beredistributed to other locations on the body 502 to improve performance,as desired. For example, if a mass of a golf club head is maintained andthe solid material above a solid CG plane and rearward of the front faceis replaced by a lattice structure, the reduced density provided by thelattice structure may enable mass to be redistributed to other regionsof the golf club. In some embodiments, it may be desirable to lower a CGdefined by a factory finished golf club head, when compared to asolid-material golf club head. In this embodiment, the mass saved byincorporating the lattice structure may be redistributed toward the soleof the golf club head. Redistributing this weight may further lower theCG of the golf club head and this process may repeat until the CG andthe redistribution of the saved mass replaced by a lattice structureconverge. That is, the golf club head may continue to be replaced withlattice structure in design, until the amount of volume replaced by alattice structure and the redistributed mass converge on a CG location.Thus, the replacement of the solid material in a golf club head may bean iterative process in design and the final finish product may beproduced with a CG that balances volume replaced by lattice structureand redistributed mass.

Referring to FIGS. 51 and 52 , in some embodiments, the latticestructure 504 may be externally visible and form at least a portion ofthe topline 528. In some instances, a golfer may not wish to view thelattice structure 504 at address (i.e., along the topline 528).Referring to FIGS. 53 and 54 , in some embodiments, the topline 528 maybe formed by solid material, for example, by a topline protrusion 548that extends laterally along the topline 528.

As described herein, weight distribution (e.g., CG manipulation) in agolf club head may be manipulated via additive manufacturing processes.In some embodiments according to the present disclosure, a golf clubhead may be manufactured layer by layer to include a cavity within agenerally solid portion of a golf club head. During manufacture, thecavity may be filled with a plug or weight that is not permanently boundor attached to the internal surfaces of the cavity. As such, the plug orweight may be held in place by the surrounding metal powder in thecavity but not attached to the surfaces that form the cavity. That is,the plug or weight may be arranged free-floatingly within the cavity. Inthis way, for example, once the metal powder is removed from the cavity,a position of the plug or weight within the cavity may be manipulated todistribute the weight of the plug at a desired location within thecavity. For example, an orientation of the golf club head may bemanipulated and gravity may be used to alter a position of the plug orweight within the cavity. The position of the plug or weight within thecavity may be secured, for example, by filling the cavity with a fillermaterial (e.g., a plastic resin, a foam material, etc.). In general, theplug or weight arranged within the cavity may generally define any shapeor structure that defines a weight that may be manipulated to alter aweight distribution within the golf club head. In some embodiments, theplug or weight may be fabricated from the same material as thesurrounding solid portion of the golf club head. In some embodiments,the plug or weight may be fabricated from a material that is differentthan a material that is used to fabricate the surrounding solid portionof the golf club head. In some embodiments, the plug or weight may befabricated from a material with a higher density than a material that isused to fabricate the surrounding solid portion of the golf club head.In some embodiments, the plug or weight may be fabricated from amaterial with a lower density than a material that is used to fabricatethe surrounding solid portion of the golf club head.

FIG. 55 illustrates one embodiment of a portion of a golf club head 600that includes a cavity 602 within which a plug or weight 604 is formedduring an additive manufacturing process. In some embodiments, theportion of the golf club head 600 is a portion of a body that is desiredto be formed of solid material. During additive manufacture of theportion of the golf club head 600, the layer by layer forming of theportion of the golf club head 600 enables the formation of the cavity602 and the plug 604 within the cavity 602. The plug 604 may bemanufactured such that the plug 604 is spaced from the internal surfacesthat form the cavity 602. In the illustrated embodiment, the plug 604 issurrounded by residual metal powder 606. The metal powder 606 may holdthe plug 604 in place within the cavity 602, while maintaining thedetachment between the plug 604 and the internal surfaces of the cavity602.

One or more ports 608 may be in communication with the cavity 602 toenable the removal of the metal powder 606 after the portion of the golfclub head 600 is manufactured. In the illustrated embodiment, theportion of the golf club head 600 includes two ports 608 arranged atopposing sides of the cavity 602. In some embodiments, the portion ofthe golf club head 600 may include more or less than two ports 608arranged in any orientation that connects to the cavity 602.

After the portion of the golf club head 600 is manufactured, pressurizedfluid (e.g., gas), a vacuum, a brush, a tool, or gravity may be appliedto the one or more ports 608 to remove the excess metal powder 606surrounding the plug 604. As illustrated in FIG. 56 , once the metalpowder 606 is removed, the plug 604 may be free to move within thecavity 602. In this way, for example, a position of the plug 604 may bemanipulated to alter a weight distribution within the portion of thegolf club head 600. In the illustrated embodiment, the cavity 602 andthe weight or plug 604 defines a generally cylindrical shape. In someembodiments, the cavity 602 and the weight or plug 604 may define anyshape (e.g., rectangular, polygonal, or any other 3-D shape) as requiredby the shape and structure defined by the portion of the golf club head600 within which the cavity 602 is arranged. For example, in someembodiments, the cavity 602 and the plug or weight 604 may definesimilar shapes. In some embodiments, the weight or plug 604 may define adifferent shape than the cavity 602 as long as the weight or plug 604 iscapable of displacing with in the cavity 602, once the excess materialis removed from the cavity 602.

In the illustrated embodiment, the design and shape of the cavity 602and the plug 604 enable the weight distribution to be moved in a lateraldirection (e.g., left and right from the perspective of FIG. 56 ). Insome embodiments, the design and shape of the cavity 602 and the plug604 may be altered to enable the weight distribution within the portionof the golf club head 600 to be moved in any direction, as desired. Forexample, the cavity 602 and the plug 604 may be designed to allow forthe weight distribution to me moved in a heel-toe direction, asole-topline direction, an oblique direction, and/or between a frontface and a rear face within the portion of the golf club head 600.Moving the weight distribution, via movement of the plug 604 to adesired location may alter the performance characteristics of a golfclub head, for example, by moving the CG and/or placing more weight in aheel or a toe of the golf club head.

Once the plug 604 is positioned in a location within the cavity 602according to a desired weight distribution, the cavity 602 may be filledwith a low-density filler material to secure the position of the plug604 within the cavity 602. For example, the low-density filler materialmay be a plastic material, a resin material, and/or a foam material.

In some embodiments, binder material may be selectively added aroundsolid portions of a golf club head to form a border or shell surroundedby metal powder. Then, during the sintering post-processing stage themetal powder enclosed within the border may solidify forming theappropriate solid portion of a golf club head. In this way, for example,use of a binder during a binder jetting process may be reduced whileprinting golf club heads, thereby improving manufacturing costs andefficiency.

As described herein, at least a portion of a golf club head that ismanufactured using an additive manufacturing process may include a solidportion (e.g., a volume region that is intended to be solid metal in thefactory finish part). In some embodiments, an additive manufacturingprocess according to the present disclosure may improve efficiency andquality of the manufactured part by forming a boundary that includes atleast one layer around a portion of a golf club head and post-processingthe portion of the golf club head form the portion of the golf club headwithin the boundary as a solid portion.

For example, as described herein, the material deposit 208 formed on thepost-printed component 204 and the solid portion 349 on the iron-typegolf club head 300 may be formed from solid material (e.g., solidmetal). In some embodiments, these solid material portions on a golfclub head may be formed using an additive manufacturing process byprinting a boundary that includes at least one layer of printed materialand surrounds a volume of unprinted material (e.g., metal powder). Forexample, the material deposit 208 or the solid portion 349 may be formedby printing a boundary that encloses a volume and is formed by at leastone layer during an additive manufacturing process. The volume encloseby the boundary may be filled with powdered metal and, thereby, may beconstrained (i.e., cannot move) within the volume. The manufactured golfclub head may then by sintered, which transitions the powdered metalenclosed within the volume to solid material (e.g., solid metal). Byonly requiring at least one layer of material to form a solid volume ona golf club head, the amount of time, binder material (e.g., for abinder jetting process), and/or power (e.g., for a SLM or a DMLSprocess) may be reduced, which may provide reduced costs and increaseefficiency during the additive manufacturing process.

FIGS. 57-59 illustrate embodiments of a cross-section of a solid volumeof a golf club head that is manufactured during an additivemanufacturing process. In the illustrated embodiments, a solid volume700 includes a boundary 702. In some embodiments, the boundary 702 maybe formed by at least one layer that is created during an additivemanufacturing process. In some embodiments, the boundary 702 may beformed by at least two, at least three, at least four, or five or morelayers during an additive manufacturing process. The boundary 702 mayenclose the solid volume 700 and the powdered metal arranged within thesolid volume 700. The powdered metal enclosed by the boundary 702 may bemaintained or supported by the boundary 702 (i.e., prevented fromdisplacing after the additive manufacturing process), once the boundary702 is fully formed. With the boundary 702 fully formed, the powderedmetal enclosed therein may be formed into solid metal via a sinteringprocess. In some embodiments, forming solid metal portions in a golfclub head via sintering powdered metal enclosed by a boundary mayproduce higher densities when compared to solid metal portions that areformed completely layer by layer. In this way, for example, the cost andefficiency of the additive manufacturing process may be improved forcreating a golf club head and the quality of the manufactured part maybe improved.

As illustrated in FIGS. 57-59 , the cross-sectional shapes of the solidvolumes 700 may take various shapes and sizes. In the illustratedembodiments, the boundary 702 formed around the solid volume 700 may bea rectangular, a round, or an oval shape. In some embodiments, theboundary 702 and/or the solid volume 700 may take any shape or size thatis required by the desired factory finish golf club head. For example,any solid portion of a golf club head may be enclosed with a boundarythat takes any shape, and the golf club head may be sintered totransition the volume enclosed by the boundary into solid material.

As described herein, additive manufacturing provides several design,manufacturing, and performance benefits for golf club heads. Additivemanufacturing also provides several advantages to the development orprototyping of golf club heads. For example, an entire set of iron-typegolf club heads may be printed within a single build platform (e.g., apowdered metal bed used in binder jetting, DMLS, SLM, etc.). As such, anentire set of iron-type golf club heads may be printed and tested in asingle build job, which differs, for example, from a forging processwhere the golf club heads are formed one at a time. Alternatively oradditionally, multiple iterations of a golf club head design may beprinted and tested during a single build job.

As described herein, in some embodiments according to the presentdisclosure, at least a portion of a golf club head may be manufacturedvia an additive manufacturing process. In some embodiments, a golf clubhead may be at least partially manufactured, or at least partiallyformed via a mold that is manufactured, via an additive manufacturingprocess. For example, a face insert that defines a striking face or afront face of a golf club head may be designed to include a 3-Dstructure that improves performance. In some embodiments, a rear side ofa front face on a golf club head may include a lattice structure or aribbed structure.

For example, as illustrated in FIG. 60 , a face insert 800 defines afront face or striking face of a wood-type golf club head and mayinclude a lattice structure 802 arranged on a rear side of the frontface or striking face. In the illustrated embodiment, the latticestructure 802 includes generally triangularly-shaped unit cells thatvary in density, surface area, or volume along the rear side of the faceinsert 800. In some embodiments, the lattice structure 802 may defineany size or shape according to the lattice structures described herein.In any case, the lattice structure 802 may vary in one or more of unitcell type, unit cell geometry, unit cell size, segment length, segment,thickness, segment volume, and unit cell density at one or morelocations along the rear side of the face insert 800. In someembodiments, the variability in the lattice structure 802 along the rearside of the face insert 800 may provide improved performance, whencompared to a lattice structure with constant properties.

In some embodiments, the incorporation of a lattice structure into astriking face on a wood-type golf club head may enable the striking faceto define a reduced thickness, for example, when compared to a strikingface fabricated solely from a solid material, due to the stiffnessprovided by the lattice structure. That is, the incorporation of alattice structure, or a ribbed structure (see FIG. 61 ), on a strikingface of a wood-type golf club head may provide added stiffness, whichenables a thickness of the solid portion (i.e., a thickness defined bythe portion of the striking face that does not include an added 3-Dstructure) to define a reduced thickness when compared to a strikingface fabricated solely from solid material.

Turning to FIG. 61 , in some embodiments, a face insert 810 may includeof a wood-type golf club head may include a ribbed structure 812arranged on a rear side of a striking face. In the illustratedembodiment, the ribbed structure 812 may include a solid portion 814that defines a generally solid protrusion that protrudes from the rearside of the face insert 810 and a plurality of ribbed segments 816 thatextend along the rear side of the striking face (e.g., generally in asole-topline direction or a vertical direction from the perspective ofFIG. 61 ). The plurality of ribbed segments 816 may be spaced laterally(e.g., in a left-right direction from the perspective of FIG. 61 ) alongthe rear side of the face insert 810.

In some embodiments, the 3-D structures incorporated onto the strikingfaces of wood-type golf club heads may be difficult to manufacture usingconventional manufacturing processes. Additive manufacturing processesmay be leveraged to enable efficient and accurate manufacturing of thesestriking faces of wood-type golf club heads. For example, FIG. 62illustrates a face insert 820 that is based on the face insert 810 andmanufactured via an additive manufacturing process and may be used in acasting process. In some embodiments, the face insert 820 may bemanufacturing out of an investment casting material (e.g., wax) and maybe manufactured via an additive manufacturing process. In someembodiments, conventional, non-additive manufacturing processes may notbe able to create the 3-D structure arranged on the rear side of thestriking faces described herein, for example, do to the presence of alattice structure, an undercut, or a gap. Additive manufacturing may beleveraged to efficiently and accurately manufacture a face insert 820.Once the face insert 820 is manufactured via an additive manufacturingprocess, the face insert 820 may be used to create a casting mold, oranother mold (e.g., metal injection molding mold), of a striking face ofa wood-type golf club head by shelling the mold with a slurry to form ashell. Once the shell has formed, the investment casting material (e.g.,wax) may be burned out and metal may be poured into the cavity definedby the shell to form a casting of the face insert. As illustrated inFIG. 63 , the casting mold or other type of mold may be used tomanufacture the striking face of a wood-type golf club head with anaccurate representation of the desired 3-D structure arranged on therear side of the striking face. The manufactured striking faceillustrated in FIG. 63 may then be post-processed to conform to factoryfinish standard and may be attached to a club head body.

In some embodiments, the additive manufacturing of a mold, or astructure that is used to make a mold in an investment casting process,may be used to manufacture iron-type golf club heads. For example, FIG.64 illustrates a club head mold 830 for an iron-type golf club head thatmay be manufacture via an additive manufacturing process. In someembodiments, the club head 830 may be manufactured out of an investmentcasting material (e.g., wax). The manufacture of the club head 830 viaan additive manufacturing process may enable the creation of uniqueundercuts and intricate geometries, for example, arranged on a rearsurface or rear cavity of an iron-type golf club head, among otherlocations. For example, FIGS. 65 and 66 illustrated a 3-D structure thatmay be incorporated into the club head 830 of FIG. 64 .

In general, the use of a wax pattern mold that is printed via anadditive manufacturing process may increase efficiency, decrease costs,and enable the creation of more complex club head geometries, whencompared to convention manufacturing processes. For example, creating awax pattern mold via an additive manufacturing process does not requiretooling when creating a design of the mold. A 3-D model of the mold maybe created in 3-D printing software, where conventional investmentcasting mold requires the creation of a wax tool. Once the part isdesigned in 3-D printing software, the wax pattern mold may be printedvia an additive manufacturing process with casting gates, whileconventional investment castings require wax to be injected into the waxtool.

As described herein, in some embodiments, a golf club head may berequired to be sintered after manufacture via an additive manufacturingprocess. In these embodiments, a support structure or fixture may berequired to aid in maintaining orientation and shape of the green partduring sintering. FIGS. 67 and 68 illustrated one embodiment of asintering support 900 that may be used to support a golf club headduring sintering. In the illustrated embodiment, the sintering support900 may be used to support an iron-type golf club head during sintering.The sintering support 900 may include a face surface 902, a hoselsurface 904, and a support wall 906. The hosel surface 904 may extendfrom one side of the face surface 902 at an angle that is defined by alie angle of the golf club head. The support wall 906 may extendgenerally perpendicularly from a side of the face surface 902 that isopposite to the hosel surface 904.

In the illustrated embodiment, the face surface 902 may be arrangedgenerally parallel to a sintering plane S that the sintering support 900rests on during sintering. In this way, for example, when a golf clubhead is arranged on the sintering support 900, the face surface 902orients a front face or striking face of a golf club head generallyparallel to the build plane and provides support to the front face orstriking face. The arrangement and support of the front face or strikingface provided by the sintering support 900 aids in reducing orpreventing warping of the golf club head geometry during sintering. Inaddition, the angle between the face surface 902 and the hosel surface904 being equal to a lie defined by the golf club head further aids inreducing or preventing warping of the golf club head geometry duringsintering.

Referring to FIGS. 69 and 70 , in some embodiments, the sinteringsupport 900 may angle the golf club head supported thereon, such that ahosel of the golf club head is arranged generally perpendicular to thesintering plane S or generally parallel to a direction of gravity. Inthis way, for example, the sintering support 900 may further aid inpreventing warping of the club head geometry during the sinteringprocess. In the illustrated embodiment, a bottom edge 908 of the supportwall 906 may be arranged at an angle relative to the face surface 902.When the bottom edge 908 of the support wall 906 is placed on thesintering plane P, the angle between the bottom edge 908 of the supportwall 906 and the face surface 902 may arrange a hosel 910 of a golf clubhead 912 in a direction that is generally perpendicular to the sinteringplane P or generally parallel to a direction of gravity. In thisorientation, the face surface 902 may be angled relative to thesintering plane S. The orientation of the hosel 910 in a direction thatis generally perpendicular to a direction of gravity may preventmovement of the hosel 910 during sintering, which maintains the lie andloft defined by the golf club head 912 pre-sintering.

In some embodiments, the sintering support 900 may be fabricated via anadditive manufacturing process. For example, the face surface 902, thehosel surface 904, and the support wall 906 may be formed layer by layerby an additive manufacturing process.

Any of the embodiments described herein may be modified to include anyof the structures or methodologies disclosed in connection withdifferent embodiments. Further, the present disclosure is not limited toclub heads of the type specifically shown. Still further, aspects of theclub heads of any of the embodiments disclosed herein may be modified towork with a variety of golf clubs.

As noted previously, it will be appreciated by those skilled in the artthat while the disclosure has been described above in connection withparticular embodiments and examples, the disclosure is not necessarilyso limited, and that numerous other embodiments, examples, uses,modifications and departures from the embodiments, examples and uses areintended to be encompassed by the claims attached hereto. Variousfeatures and advantages of the invention are set forth in the followingclaims.

INDUSTRIAL APPLICABILITY

Numerous modifications to the present disclosure will be apparent tothose skilled in the art in view of the foregoing description.Accordingly, this description is to be construed as illustrative onlyand is presented for the purpose of enabling those skilled in the art tomake and use the invention. The exclusive rights to all modificationswhich come within the scope of the appended claims are reserved.

We claim:
 1. A golf club head, comprising: a body including a top side,a sole, and an internal cavity arranged between the top side and thesole, the body defining a heel region and a toe region; a first weightarranged in the heel region; a second weight arranged in the toe region,wherein the first weight and the second weight are fabricated from adifferent material than the body; a retention feature extending from thetop side within the internal cavity, wherein at least one of the firstweight or the second weight is engaged with the retention feature withinthe internal cavity; and a lattice structure arranged within theinternal cavity between the first weight and the second weight andformed layer by layer via an additive manufacturing process, wherein, inan assembled configuration, the lattice structure is visible from anexterior of the golf club head through at least one window of the body,wherein the first weight, the second weight, and the lattice structureare positioned entirely within the internal cavity.
 2. The golf clubhead of claim 1, wherein the body and the retention feature arefabricated via the additive manufacturing process.
 3. The golf club headof claim 1, wherein the lattice structure is arranged adjacent to thetop side.
 4. The golf club head of claim 1, wherein the latticestructure is arranged adjacent to the sole.
 5. The golf club head ofclaim 1, further comprising an aperture or slot formed in the body, anda hosel extending from a heel side of the body and defining a hoselcavity formed therein.
 6. The golf club head of claim 5, wherein a flowpath is defined along the hosel cavity, the lattice structure, and theslot or aperture to enable removal of excess material from the internalcavity after the additive manufacturing process.
 7. The golf club headof claim 1, wherein the lattice structure is formed layer by layer alonga build plane, and wherein when the build plane is oriented parallel toa normal defined by a front face of the body, a lattice build angledefined between a lattice plane and the build plane is greater than orequal to about 30 degrees.